WO2024220971A1

WO2024220971A1 - Optical lenses, optical components, and methods of manufacturing optical components

Info

Publication number: WO2024220971A1
Application number: PCT/US2024/025665
Authority: WO
Inventors: James Hedrick; Richard Schmidt; Michael Flynn; Eric POTEMPA
Original assignee: Azul 3D, Inc.
Priority date: 2023-04-21
Filing date: 2024-04-22
Publication date: 2024-10-24
Also published as: WO2024220971A9

Abstract

Apparatus, methods and computer-readable media storing instructions for producing an optical lens body by continuous vat polymerization. The methods may include, and the apparatus may be used for projecting radiation into a resin; drawing a gel body away from a projector that provides the radiation; and controlling a thickness of a pre-gelation zone extending from the resin to the gel body. The controlling may include receiving a thickness control-value. The controlling may include setting a rate of the drawing to obtain a thickness that corresponds to the thickness control-value. The controlling may include setting an intensity of radiation that corresponds to the thickness control-value. The controlling may include receiving a thickness control-value; and setting a rate of the drawing and an intensity of the radiation to obtain a thickness that corresponds to the thickness control-value. The setting may be based on a resin activation energy.

Description

OPTICAL LENSES, OPTICAL COMPONENTS, AND METHODS OF MANUFACTURING OPTICAL COMPONENTS FIELD OF TECHNOLOGY [0001] The technology disclosed herein relates to an optical lens, and more particularly to an optical lens and optical components produced preferably by continuous vat polymerization and methods of producing an optical lens and optical components preferably via continuous vat polymerization. BACKGROUND [0002] In conventional applications of photopolymerization based 3D printing, commonly referred to as vat polymerization, a layer-by-layer process is utilized. In this process, a small layer of resin is cured and then moved away from a contact point to allow a subsequent layer of resin to cure. The layers may be added in either a top-down or bottom-up method. In the top-down method, the cured layer of resin is created by shining polymerizing light at the surface of a pool of resin and then lowering that layer deeper into that pool of resin to expose uncured resin to the surface. In the bottom-up method, a cured layer is created by shining polymerizing light through a window at the bottom of a pool of resin and lifting that layer up out of the liquid vat to expose uncured resin to the window. The shape of the printed part is dictated by the area and shape of the energy exposure from the polymerizing light. The printed part can be built by separating the printed part from the area of energy exposure, or printing interface, and curing the printed part in the third dimension. The bottom-up method has several technical advantages over the top-down method, such as the ability to control resin layer thickness more precisely. [0003] Developments in the field of vat polymerization have allowed for the creation of additional techniques and methods having a variety of benefits. One category of vat polymerization is Digital Light Processing (DLP), which makes use of a projector or array of projectors in order to trigger polymerization in a large area of resin at once. Further advancements in the field of DLP 3D printing have allowed for the development of continuous printing technologies that can allow for DLP printers to produce articles at a significantly faster rate. One of these technologies is known as High-Area Rapid Printing (HARP), which makes use of a liquid interface layer between the resin in the vat and the window through which the projector emits light into the resin. The interface layer present in HARP technology both provides a method for reducing adhesion forces and temperature control of the exothermic polymerization reactions of the resin, allowing for continuous bottom-up vat polymerization. Continuous 3D printing capabilities allow for an increase in printing speed and mechanical properties not otherwise available to traditional layer by layer techniques. The continuous capability of modern 3D printing has the potential to create significant advancements in a variety of fields. [0004] One field in which continuous 3D printing can provide unique benefits is the field of optical lens production. Traditional optical lens production for eyeglasses involves creating optical lenses from large, pre-manufactured lens blanks. These lens blanks are typically produced by classic manufacturing techniques including injection or cast molding, and they are constructed from optically transparent, high refractive index materials such as polycarbonate or glass. Lens blanks are typically produced having a specific front curvature, then the rest of the blank undergoes the necessary processing in order to be customized and fitted for a specific frame. Lens blanks are typically constructed from either thermoset plastics, which form chemical bond and retain their shape after curing under heat, or thermoplastics, which melt under high heat and can be re-cured. These lens blanks are fixed to a support structure and undergo grinding, shaping, polishing, coating, etching, tinting, edging, and the like with the end result being an optically functional lens that can be fitted into the desired frame to make a pair of eyeglasses. Ophthalmic lenses are used to correct a variety of vision-related medical conditions, and they are a form of optical lens having a certain shape, structure, and material which allow for vision correction when customized for a specific user. This manufacturing process requires a high amount of inventory for a lens manufacturer to hold at once as many different pre-manufactured lens blanks need to be available at any time to account for the large variance in optical lens necessities. Additionally, these blanks

‐ 2 ‐ are typically much larger than the final optical lens, and the processing of these blanks results in a large amount of waste.3D printing can account for some of these issues; however, traditional layer- by-layer techniques struggle to produce lenses having the necessary optical properties. Continuous 3D printing can account for these issues, and it can allow for even further developments in optical lens development while also having the capability of manufacturing these lenses at a much greater speed than traditional 3D printing techniques. Additionally, continuous vat polymerization is capable of creating some lenses and associated products that are completely unavailable to traditional manufacturing techniques. [0005] As stated above, one of the most common uses of optical lenses is their use in eyeglasses, and, more particularly, their use in ophthalmic eyeglasses. Ophthalmic lenses are corrective in nature and used to alter the images that the eye perceives to compensate for a visual acuity disorder. The most common visual disorders are myopia and hyperopia, or near sightedness and far sightedness. These conditions occur because the image produced by the human eye’s lens focuses at a point before or after the retina, respectively. A properly prescribed ophthalmic lens adjusts the point at which an image focuses, called the focal point, to compensate for issues with the human eye’s lens and its distance from the eye’s retina in order to correct visual acuity issues. Another common visual acuity disorder is astigmatism, which occurs when the surface of the lens, cornea or both is/are not smooth. This results in a visual streak of distortion and is corrected via a lens that compensates for this uneven curvature. Although these problems are incredibly common, each person requiring corrective ophthalmic lenses has unique needs to compensate for their individual acuity issues. 3D printing as a manufacturing process is positioned to manufacture ophthalmic lenses as each lens can be manufactured with the required ophthalmic correction in mind. Continuous 3D printing can, in turn, overcome challenges that layer-by-layer techniques have in manufacturing quality optical lenses. SUMMARY [0006] Apparatus, methods and computer-readable media storing instructions for producing an optical lens body by continuous vat polymerization. The methods may include, and the apparatus may be used for projecting pixelated radiation into a resin; drawing a gel body away from a projector that provides the radiation; and controlling a beam characteristic of each pixel in the pixelated radiation.

‐ 3 ‐ BRIEF DESCRIPTION OF DRAWINGS [0007] The objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: [0008] FIG.1 shows schematically illustrative apparatus in accordance with the principles of the invention. [0009] FIG. 2A shows schematically illustrative apparatus in accordance with the principles of the invention. [0010] FIG. 2B shows schematically illustrative apparatus in accordance with the principles of the invention. [0011] FIG.3 shows schematically illustrative apparatus in accordance with the principles of the invention. [0012] FIG.4 shows schematically illustrative apparatus in accordance with the principles of the invention. [0013] FIG.5 shows schematically illustrative apparatus in accordance with the principles of the invention. [0014] FIG.6 shows schematically illustrative apparatus in accordance with the principles of the invention. [0015] FIG.7 shows illustrative information in accordance with the principles of the invention. [0016] FIG.8 shows illustrative information in accordance with the principles of the invention. [0017] FIG.9 shows schematically illustrative apparatus in accordance with the principles of the invention. [0018] FIG.10 shows schematically illustrative apparatus in accordance with the principles of the invention. [0019] FIG.11 shows schematically illustrative apparatus in accordance with the principles of the invention. [0020] FIG.12 shows schematically illustrative apparatus in accordance with the principles of the invention. [0021] FIG.13 shows schematically illustrative apparatus in accordance with the principles of the invention.

‐ 4 ‐ [0022] FIG.14 shows steps of an illustrative process in accordance with the principles of the invention. [0023] FIG.15 shows steps of an illustrative process in accordance with the principles of the invention. [0024] FIG.16 shows schematically a condition in apparatus in accordance with the invention. [0025] FIG.17 shows schematically illustrative apparatus in accordance with the principles of the invention. [0026] FIG.18 shows schematically illustrative apparatus in accordance with the principles of the invention. [0027] FIG.19 shows schematically illustrative apparatus in accordance with the principles of the invention. [0028] FIG.20 shows schematically illustrative apparatus in accordance with the principles of the invention. [0029] FIG.21 shows schematically illustrative apparatus in accordance with the principles of the invention. [0030] FIG.22 shows schematically illustrative apparatus in accordance with the principles of the invention. [0031] FIG.23 shows schematically illustrative apparatus in accordance with the principles of the invention. [0032] FIG.24 shows schematically illustrative apparatus in accordance with the principles of the invention. [0033] FIG.25 shows schematically illustrative apparatus in accordance with the principles of the invention. [0034] FIG.26 shows schematically illustrative apparatus in accordance with the principles of the invention. [0035] FIG.27 shows schematically illustrative apparatus in accordance with the principles of the invention. [0036] FIG.28 shows schematically illustrative apparatus in accordance with the principles of the invention. [0037] FIG.29 shows schematically illustrative apparatus in accordance with the principles of the invention.

‐ 5 ‐ [0038] FIG.30 shows schematically illustrative apparatus in accordance with the principles of the invention. [0039] FIG.31 shows schematically illustrative apparatus in accordance with the principles of the invention. [0040] FIG.32 shows schematically illustrative information in accordance with the principles of the invention. [0041] FIG.33 shows schematically illustrative information in accordance with the principles of the invention. [0042] FIG.34 shows schematically illustrative information in accordance with the principles of the invention. [0043] FIG.35 shows schematically illustrative information in accordance with the principles of the invention. DETAILED DESCRIPTION [0044] While the present invention is susceptible of embodiment in many different forms, there are shown in the drawings and will be described herein in detail specific exemplary embodiments thereof, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated. In this respect, before explaining at least one embodiment consistent with the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of components set forth above and below, or as described in the examples. Methods and apparatuses consistent with the present invention are capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. [0045] The technology described herein pertains to optical lenses and optical components manufactured preferably via continuous DLP vat polymerization 3D printing and methods of producing optical lenses and optical lens precursors preferably via continuous DLP vat polymerization. The technology described herein also pertains to software for controlling a continuous DLP vat polymerization device as it is performing a method for producing optical lenses and optical precursors. For the purposes of this invention an “additive manufacturing

‐ 6 ‐ process” refers to the selective polymerization of an article from a material and any post- production processing that the article must undergo before the desired final product has been created. For the purposes of this invention, “continuous vat polymerization”, “layer-by-layer techniques”, “stereolithography”, “inkjet head printing” and other references specifically relating to the process of selectively polymerizing a material refer to processes to create a solid article from a material as a part of an additive manufacturing process. For the purposes of this invention, an “optical component” is defined as an article designed to be used with or preferably comprising an optical lens and/or optical lens precursor. For the purposes of this invention, an article “precursor” is defined as a part destined to become an article after at least one further processing step. For the purposes of this invention, a “green body” or “optical green body” describes the optical lens, optical lens precursor or optical component produced by selective polymerization wherein said green body has not achieved complete polymerization of resin throughout. Optical and Ophthalmic Lens Parameters [0046] In an aspect, this invention provides an additively manufactured optical lens meeting the necessary optical and safety requirements for use in eyeglasses. Optical lens as defined herein refers to an optically transparent article through which light may be transmitted. Typically, optical lenses make use of multiple variables in order to control how light is transmitted through the lens in order to create a predictable, repeatable optical result. The most important variables to consider when manufacturing an optical lens are the geometry of the lens and the material and optical properties of the material out of which the lens is made. Examples of geometric variables include the diameter, shape, center point (mechanical axis), and the direction and radius of the curves of each face of the lens, if any. Examples of material and optical properties include index of refraction, mechanical strength, chromatic dispersion, sphere power, density, UV absorption, optical clarity, and homogeneity. In optical lenses, an optical axis exists that may differ from the mechanical axis. The mechanical axis of a lens is the geometric center of the lens. The optical axis is the axis passing through the center of the curvature of the lens. By controlling these different variables, predictable patterns of light transmission through the lens can be determined. [0047] Ophthalmic or corrective lens as defined herein refers to an optical lens that is specifically designed to compensate for a person’s unique visual acuity disorder based on optical data. Ophthalmic lenses make use of specific applications of the variables of optical lenses and the

‐ 7 ‐ predictable optical patterns that they generate to be able to predictably correct a person’s unique visual acuity disorder. [0048] Lenses can take a variety of shapes, and different shapes provide different corrective capabilities. One category of shapes is spherical lenses, which are lenses that have a constant curvature across all meridians (any vertical axis). The three general spherical shapes that optical lenses take are flat, concave, or convex. Flat lenses can provide very little corrective capabilities, and they are typically used types of eyeglasses that do not provide visual acuity correction and instead provide some other benefit, such as non-corrective sunglasses, non-corrective protective eyewear, or non-corrective athletic eyewear. Convex lenses are lenses that possess at least one outward curve, or a curve that is thicker at the mechanical and optical axis of the lens and thinner on the edges. Convex lenses cause light to converge as it passes through the lens, and its use in optometry is to correct for hyperopia. Convex lenses cause an image to be perceived as closer because of the convergence of light as it passes through the lens. Concave lenses are lenses that possess at least one inward curve, or a curve that is thicker on the edges and thinner on the mechanical and optical axis. Concave lenses cause light to diverge outward as it passes through the lens causing an image to be perceived as further away because of the divergence of light as it passes through the lens. Concave lenses are used in optometry to correct for myopia. For a given lens material, the greater the degree of the curve, the greater the corrective strength of the lens. This strength of a lens measures the focal distance of the lens. For a convex lens, the focal distance is positive and is the point at which light passing through the lens converges. For a concave lens, the focal distance is negative and is the point at which the light diverging outward from the lens would converge on the opposite side. Lens strength, also known as sphere power, is measured using Diopters, which is a unit of refractive power equal to the reciprocal of the focal distance in meters. In an embodiment, this invention provides an optical lens having at least one spherical curve. In an embodiment, this invention provides an optical lens having a concave curve. In an embodiment, this invention provides an optical lens having a convex curve. [0049] In addition to spherically curved lenses, cylindrically curved lenses are also used in optical lenses. In corrective lenses, cylindrically curved lenses are primarily used to correct for astigmatism, or an irregularly shaped cornea resulting in multiple focal points within a person’s eye. Cylindrically curved lenses focus or defocus light in a single direction or line because they are only curved in a single direction. Spherically curved lenses, on the other hand, converge light

‐ 8 ‐ onto a single point. A corrective cylindrical lens will have different curvatures and different meridians along the lens allowing. Much like sphere power, cylinder power is measured in Diopters on the same scale. Further, corrective cylindrical lenses used for astigmatism have an axis, which describes the position of the cylinder in the lens corresponding with the irregular shape of the cornea. Cylindrical lenses converge or diverge an image in the direction perpendicular to this axis, while not altering images parallel to this axis. This axis based correction differs from spherical lenses as spherical lenses converge or diverge light in all directions to or away from a single point. Lens power is determined by the formula: ^_{^ ൌ ^ ^^ െ 1^^} ^{1 1} ^_{^ െ} _{^ ^} _{^ ^ଶ} where P is the power of the lens, n of the lens material, and R1 and R2 are

the radius of the curvatures on of the lens, respectively. In an embodiment, this invention provides an additively manufactured optical lens having at least one cylindrical curve. [0050] Lens shapes, among other variables, are used in combination with one another to generate corrective lenses customized to each user’s visual acuity. For example, one optical lens can consist of a convex curve on one face of the lens having a strength of +3.00 Diopters and a concave curve on the other face having a strength of -4.00 Diopters resulting in the lens having an overall strength of -1.00 Diopters, or the sum of the strength of the two curves in the lens. A suitable manufacturing process should preferably be capable of manufacturing lenses having a wide range of potential shapes and curvatures.3D printing is perfectly suited to this customization. All forms of 3D printing make use of CAD designs that dictate the pattern of polymerization of materials to be formed into an additively manufactured article. This makes 3D printing a very capable system of creating personally customized lenses based on optical data generated from a user that can account for any geometry. In an aspect, this invention provides an additively manufactured optical lens having at least two curvatures, the at least two curvatures having independent sphere powers. In an aspect, this invention provides an additively manufactured optical lens having a total spherical power between -50.00 and +50.00 diopters, -40.00 and +40.00 diopters, -30.00 and +30.00 diopters, -20.00 and +20.00 diopters, -10.00 and +10.00 diopters, -8.00 and +8.00 diopters, -7.00 and +7.00 diopters, -6.00 and +6.00 diopters, -5.00 and +5.00 diopters, -4.00 and +4.00 diopters, -3.00 and +3.00 diopters, -2.00 and +2.00 diopters, -1.00 and +1.00 diopters, or -0.50

‐ 9 ‐ diopters and +0.50 diopters. In an aspect, this invention provides an additively manufactured optical lens having a total cylindrical power between -6.00 and +6.00 diopters, -5.00 and +5.00 diopters, -4.00 and +4.00 diopters, -3.00 and +3.00 diopters, -2.00 and +2.00 diopters, -1.00 and +1.00 diopters, or -0.50 diopters and +0.50 diopters. [0051] The primary component of any optical lens material is that the material is light transmissive. This light transmissive is measured using haze percentage, which is defined as the percentage of light diffused by more than 2.5⁰ when passing through the material perpendicularly. When light is diffused at this angle or greater, the ability of a lens to predictably alter the focal point of an image is reduced. Perfectly optically transparent materials, such as glass, have a haze percentage of 0.0%. Plastic materials used in typical optical lens manufacture, such as polycarbonate, have a haze percentage of 1.0%. In an aspect, this invention provides an additively manufactured optical lens after printing, but before polishing, having a haze percentage less than 6.0%, more preferably less than 5.0%, more preferably less than 4.0%, more preferably less than 3.0.%, or even more preferably less than 2.0%. In another aspect, this invention provides an additively manufactured optical lens after printing, but before polishing, having a haze percentage of between 4.0% and 6.0%, and more preferably between 3.0% and 6.0%. In another aspect, this invention provides an additively manufactured optical lens having a haze percentage of between 3.0% and 5.0%, more preferably between 2.0% and 4.0%, more preferably between 1.0% and 4.0%, or more preferably between 1.0% and 3.0%. [0052] In an aspect, this invention provides an additively manufactured, finished optical lens after polishing and coating having a haze percentage less than 22.0%, more preferably less than 11.0%, more preferably less than 00.50%, and more preferably less than 0.22% and even more preferably less than 0.1%. In another aspect, this invention provides an additively manufactured, finished optical lens after polishing and coating having a haze percentage of between 0.5% and 3.0%, and more preferably between 0.5% and 1.0%. In another aspect, this invention provides an additively manufactured, finished optical lens after polishing and coating having a haze percentage of between 0.05% and 2.0%, more preferably between 0.05% and 1.0%, more preferably between 0.05% and 0.5%, or more preferably between 0.3% and 0.5%. Haze measurements can be done following ASTM D1003. This haze value above is preferably transmission haze.

‐ 10 ‐ [0053] A component of optical lenses is the light transmissive material from which the lens is constructed. One requirement of any suitable optical lens material is the index of refraction. The index of refraction of a material defines how fast light moves through the material as compared to light moving in a vacuum, and it is determined from the change in the angle of light as it passes from one material into another. The index of refraction is determined by the optical density, or absorbance, of the material, which indicates the intensity of light entering the material compared to the intensity of light leaving the material. Snell’s law can be used to determine the refractive index of a medium: ^^_^ ^{sin ^^^ ^^} ^ ^ൌ ^_{^ ൌ} ^{^} ^_{^ sin ^ ^^^} where n_a and n_b are the refractive index of the first and second mediums, respectively, v_a and v_b are the velocity of light travelling through the first and second mediums, respectively, ^^_^ is the angle of incidence, and ^^_^is the angle of refraction. Standard testing of index of refraction of a material compares the angle and speed of white light travelling through a material to light in a vacuum. In an aspect, an embodiment according to the disclosure provides an additively manufactured optical lens having index of refraction of at least 1.4, more preferably an index of refraction of at least 1.45, more preferably an index of refraction of at least 1.5, more preferably an index of refraction of at least 1.53, more preferably an index of refraction of at least 1.55, and even more preferably greater than 1.60. [0054] In an aspect, an embodiment according to the disclosure provides an additively manufactured optical lens having index of refraction of between 1.4 and 1.8, more preferably an index of refraction of between 1.45 and 1.8, more preferably an index of refraction of between 1.5 and 1.8, more preferably an index of refraction between 1.53 and 1.8, and even more preferably an index of refraction of between 1.55 and 1.8. In an aspect, this invention provides an additively manufactured optical lens having index of refraction of between 1.4 and 1.74, more preferably an index of refraction of between 1.45 and 1.74, more preferably an index of refraction of between 1.5 and 1.74, more preferably an index of refraction between 1.53 and 1.74, more preferably an index of refraction of between 1.55 and 1.74, or even more preferably an index of refraction between 1.60 and 1.74. In another aspect, this invention provides an additively manufactured optical lens having index of refraction of between 1.4 and 1.70, more preferably an index of refraction of between 1.45 and 1.70, more preferably an index of refraction of between 1.5 and

‐ 11 ‐ 1.70, more preferably an index of refraction between 1.53 and 1.70, more preferably an index of refraction of between 1.55 and 1.70, or even more preferably an index of refraction between 1.60 and 1.70. In another aspect, this invention provides an additively manufactured optical lens having index of refraction of between 1.4 and 1.65, more preferably an index of refraction of between 1.45 and 1.65, more preferably an index of refraction of between 1.5 and 1.65, more preferably an index of refraction between 1.53 and 1.6, or even more preferably an index of refraction of between 1.55 and 1.65. [0055] In another aspect, an embodiment according to the disclosure provides an additively manufactured infrared lens having index of refraction of at least 1.70, more preferably an index of refraction of at least 1.80, more preferably an index of refraction of at least 1.90, more preferably an index of refraction of at least 2.00, and even more preferably greater than 1.60. In an aspect, this invention provides an additively manufactured infrared lens having index of refraction of between 1.7 and 2.3, more preferably an index of refraction of between 1.7 and 2.2, or more preferably an index of refraction of between 1.7 and 2.1, [0056] When manufacturing a lens, the index of refraction is chosen based on the product a manufacturer is looking to manufacture. An index of refraction of 1.50-1.53 is often chosen for children’s lens.1.55-1.60 is used for adults with single vision lens. For older adults needing heavy correction and wanting a lighter lens, an index if refraction of 1.58-1.74 is ideal for progressive lenses. For lenses that need infrared transparency or for use with wave guides a range of 1.70-2.9 is needed. Within that range, an ideal range of 1.70-2.10 is desirable with materials that do not have nanoparticle or microparticle fillers. [0057] Another requirement of any suitable optical lens material is its chromatic aberration or dispersion. Chromatic aberration is defined as the difference in refraction between waves of light having different wavelengths. As a result of chromatic aberration, a single material will have different indexes of refraction for different wavelengths of light. Chromatic aberration is measured using o Number, or V-Number, which is calculated based on the index of refraction for 3 standardized wavelengths of light: yellow from sodium (598.2 nm), red from hydrogen (656.3 nm), and blue from hydrogen (486.1 nm). Abbe Number is calculated using the formula: ^^ ^{^ ^^^ െ 1^}

‐ 12 ‐ where V is the Abbe Number, nD is the index of refraction of sodium yellow light, nF is the index of refraction of hydrogen blue light, and nC is the index of refraction of hydrogen red light. Materials having a high Abbe Number have low chromatic aberration, and materials having a low Abbe Number have higher chromatic aberration. In an aspect, this invention provides an additively manufactured optical lens having an Abbe value greater than or equal to 30.0, more preferably greater than or equal to 35, or more preferably greater than or equal to 40.0. In another aspect, this invention provides an additively manufactured infrared lens having an Abbe value of between 30.0 and 70.0, more preferably an Abbe value of between 40.0 and 70.0, more preferably an Abbe value of between 45.0 and 70, more preferably an Abbe value of between 50.0 and 70, or even more preferably an Abbe value of between 60.0 and 70.0. In another aspect, this invention provides an additively manufactured infrared lens having an Abbe value of between 30.0 and 80.0, more preferably an Abbe value of between 40.0 and 80.0, more preferably an Abbe value of between 45.0 and 80.0, more preferably an Abbe value of between 50.0 and 80.0, or even more preferably an Abbe value of between 60.0 and 80.0. In another aspect, this invention provides an additively manufactured infrared lens having an Abbe value of between 30.0 and 60.0, more preferably an Abbe value of between 40.0 and 60.0, more preferably an Abbe value of between 45.0 and 60.0, more preferably an Abbe value of between 50.0 and 60.0, or even more preferably an Abbe value of between 60.0 and 70.0. For IR lenses, the Abbe value can be lower since it is not used with a human eye. The Abbe value can be between 10-40. In some cases, The Abbe value cannot be measure because one or all the wavelengths of light used to measure Abbe value are not transmissive. [0058] Both the Index of Refraction and the Abbe Number are used to determine how much the focal point of an image changes as it passes through a lens. In order to achieve a certain sphere power, a blank having a suitable optical lens material is selected where both the index of refraction and Abbe Number are known. Using this knowledge, the lens is shaped to achieve the specific geometry that will give it the desired sphere power. [0059] In addition to the optical properties of the lens, mechanical properties must also be considered. Primary mechanical property concerns revolve around the safety of the user. The optical lens must not break, shatter, or in any way damage the user’s eye under reasonable conditions. Further, lenses must not deform to prevent changes in the sphere power and potential vision problems of the user. A standard ball-drop test is used to test the mechanical strength of an

‐ 13 ‐ optical lens to determine whether it meets the standards for mechanical fracture or deformation. Per ISO 14889:1997, an uncut finished lens must be able to withstand a steel ball having a 22 mm diameter dropped such that it applies approximately 100 N of force into the lens at approximately 23⁰C for approximately 10 seconds. A lens would be considered fractured if the test cracks the lens through the entire thickness of the lens into two or more pieces or if at least 5 mg of lens material detaches from the surface. To test for deformity, a piece of carbon paper is placed beneath the lens during the ISO 14889:1997 ball drop test, and a lens is considered deformed if a mark appears on this paper. In an aspect, this invention provides an additively manufactured lens meeting the ISO standards for uncut finished lenses for mechanical strength. [0060] Another parameter to consider for suitable optical lens materials is the density of the material. Typical glass materials used for optical lenses have a density between 2.5 g/cm³ to 4.3 g/cm³. Typical plastic materials used for optical lenses have a density between 1.11 g/cm³ (Trivex™) and 1.46 g/cm³ MR-174). In an aspect, this invention provides an additively manufactured optical lens having a density less than 1.5 g/cm³, more preferably less than 1.3 g/cm³, more preferably less than 1.2 g/cm³, more preferably less than 1.1 g/cm³, more preferably less than 1.0 g/cm³. In an aspect, this invention provides an additively manufactured optical lens having a density between 0.9 g/cm³ and 1.5 g/cm³, more preferably between 0.9 g/cm³ and 1.3 g/cm³, more preferably between 0.9 g/cm³ and 1.2 g/cm³, or more preferably between 0.9 g/cm³ and 1.1 g/cm³. In an aspect, this invention provides an additively manufactured optical lens having a density between 1.1 g/cm³ and 1.5 g/cm³, more preferably between 1.0 g/cm³ and 1.3 g/cm³, or more preferably between 1.1 g/cm³ and 1.3 g/cm³. [0061] In an aspect, this invention provides an additively manufactured optical lens from a given resin comprising a density less than the density of an optical lens from the given resin manufactured using standard techniques for cast molding optical.lens. A continuous vat polymerization printing process can use a given thermoset resin to additively manufacture a lens having a density lower than that of a lens manufactured through cast or pressure molding techniques using that resin. This is the result of the continuous resin flow during the continuous vat polymerization printing process, which can result in less overall cross-linking in the polymer network compared to traditional casting techniques. In an aspect, this invention provides an optical lens comprising a polymerized thermoset resin, the optical lens having a density less than an optical lens comprising the same polymerized thermoset resin manufactured using a casting process. In

‐ 14 ‐ an aspect, this density difference is at least 0.05 g/cm³, more preferably at least 0.1 g/cm³. preferably at least 0.2 g/cm³, more preferably at least 0.3 g/cm³, or more preferably at least 0.5 g/cm³. In another aspect, the density optical lens of an optical lens of the present invention can have a density between 0.05 g/cm³ and 0.5 g/cm³ lower than an optical lens comprising the same polymerized thermoset resin manufactured using a casting process, and preferably between 0.05 g/cm³ and 0.4 g/cm³ lower, between 0.10 g/cm³ and 0.5 g/cm³ lower, between 0.10 g/cm³ and 0.4 g/cm³ lower, between 0.20 g/cm³ and 0.5 g/cm³ lower, between 0.02 g/cm³ and 0.4 g/cm³ lower, between 0.30 g/cm³ and 0.4 g/cm³ lower, or between 0.30 g/cm³ and 0.5 g/cm³ lower. [0062] This is specifically used to give a pull directionality into the network to specifically align the most optically active components in the polymer backbone rather than having the most compressed network possible. Also for molecules for polarized, photochromic, or liquid crystal that need the directionality to have their desire property in the lens. For lenses that do not have these properties, it is sometimes preferrable to have a smaller density difference to no density difference as compared to optical lens made using standard techniques for cast molding optical lens. In an aspect, the density optical lens of an optical lens of the present invention compared to the density of an optical lens comprising the same polymerized thermoset resin manufactured using a casting process is 0.4 g/cm³ or less more preferably 0.3 g/cm³ or less more preferably 0.2 g/cm³ or less more preferably 0.1 g/cm³ or more and preferably less than 0.05 g/cm³ or less. Material Properties Suitable for Continuous Vat Polymerization of Optical Lenses [0063] To manufacture optical lenses using continuous vat polymerization processes that meet or exceed industry standards, resin formulations should meet certain requirements. First, the resin formulation needs to be optically transparent, unless the desired lens is a sunglasses lens or other lens where partial light absorption is desired, in which case the resin formulation should preferably be translucent. Second, the resin formulation should meet the refractive index and Abbe Number thresholds after the additive manufacturing process of the lens is complete. [0064] Continuous vat polymerization methods have additional standards that resin formulations should meet, and there are many components that can be added to a resin formulation that can significantly impact the properties of the final product. In an example, a suitable resin formulation is a thermoset resin formulation. In an embodiment, a suitable resin formulation comprises comprise(s) one or more monomer(s), one or more oligomer(s), or the like, or any combination thereof, and a potentiator. Suitable monomers and/or oligomers is/are polar or

‐ 15 ‐ nonpolar, organic or inorganic, saturated or unsaturated, mono-functional or multifunctional, or the like, or any combination thereof. Suitable monomers and/or oligomers include, but are not limited to, acrylates, methacrylate, vinyls, and the like. In an example, a resin formulation suitable for optical lens manufacture will be optically transparent. In an example, a resin formulation suitable for optical lens manufacture will be optically translucent. In an example, a suitable resin formulation further comprises a thermal initiator. In an example, a suitable resin formulation further comprises a UV inhibitor. [0065] The optical properties of resin formulation depend on specific components of the resin formulation. Non-limiting examples of monomers that affect the optical properties of a resin formulation are aromatic monomers and sulfur-containing monomers. In an embodiment, a suitable resin formulation further comprises at least one aromatic ring component. Aromatic rings may be classified by the number of functional groups bound to the ring. In an embodiment, the at least one aromatic ring component further comprises a monofunctional aromatic ring, a difunctional aromatic ring, a trifunctional aromatic ring, a tetrafunctional aromatic ring, or a combination thereof. In an embodiment, a suitable resin formulation further comprises a sulfur monomer and/or oligomer. In an embodiment, on polymerization sulfur monomers and/or oligomers are present in the polymer backbone of the resin formulation. In an embodiment, on polymerization a thiol monomer is a pendant group. Applications of Continuous Vat Polymerization of Optical Lenses [0066] In an aspect, the present invention provides an optical component having a homogenous polymer network. In an aspect, the present invention provides an optical lens having a homogenous polymer network. For the purposes of this invention, a polymer network is a “homogenous polymer network” if it lacks distinct and perceivable imperfections, such as layer lines. Traditional additive manufacturing techniques such as stereolithography, selective laser sintering and inkjet head printing make use of layer-by-layer techniques. Layer-by-layer stereolithography involves curing an entire layer of resin, then moving that previously cured layer away from the energy source and allowing fresh resin to flow in and another layer to be cured. Layer-by-layer techniques possess weak layer-to-layer cohesion, often resulting in imperfections referred to as “layer lines” or “boundary lines” present between the layers. These layer lines prevent the formation of a truly homogenous polymer network because the polymer network at the boundaries between layers differs from the polymer network of the layers themselves, which can weaken the strength of the

‐ 16 ‐ product in the z-direction, or the direction in which the object was printed. In terms of optical lens manufacturing, layer lines create visual and optical imperfections that can affect the optical properties of the lens and disrupt the visual clarity of the lens. Layer-by-layer techniques are capable of producing layers so thin that they are imperceptible to the eye, but the inconsistencies of the layer lines are still present in the polymer network. The more layer lines that are present in a lens, the more they will diffuse light as it passes through the lens. Thus, lenses produced by layer-by-layer techniques typically do not meet the haze % thresholds for use of those lenses in eyeglasses. Techniques making use of smaller layers can allow for more precision during the printing process, but it increases the prevalence of layer lines, decreases the strength of the final product, and decreases the speed of the printing process. As layers increase in depth, the necessary precision of the printing process decreases and the difference between the polymerization of the top of the layer and the bottom increases. Method for Manufacturing a lens via continuous vat polymerization [0067] Establishing a Pre-Gelation Zone Thickness (“PGZT”) can be important for printing a suitable optical lens. The Pre-Gelation Zone is the region in which a radiation-induced reaction has occurred, preferably covalent bonding between resin monomers and/or oligimers through photochemical reaction. The average static viscosity in the Pre-Gelation Zone is enhanced compared to the bulk resin. PGZT is the distance in the z-direction between the point where curing begins (i.e., covalent bonding between resin monomers and/or oligomers) and the gel point boundary (“GP”). A gel is where a resin has enough of a formed network that it holds it shape but still has a portion of liquid resin contained within the gel body. The gel point boundary is where the body initially reaches gelation as shown at boundary GP in Fig. 1. Above boundary GP, the body is either a gel and/or a solid. Below boundary GP, the body is a liquid with enhanced viscosity as compared to the bulk resin. [0068] A voxel of resin will gel when it has achieved a sufficient amount of radiation. Pre- Gelation Zone thickness is resin dependent and inversely proportional to the reactivity for a given light intensity. The reactivity may be dependent on all of the components that make up the resin including the initiators and blockers. Intensity at a depth z for a resin having a molar extinction coefficient ∈, ^^( ^^)= ^^0 ^^−∈ [ ^^ ^^] ^^. Intensity, measured in watts/cm3 determines how much energy a voxel of resin receives. Pre-Gelation Zone thickness may be increased, for example, by decreasing the photoinitiator concentration (as long as the photoinitiator concentration is not such

‐ 17 ‐ that photoinitiator becomes a blocker as well as an initiator) or decreasing the light intensity such that polymerization occurs at a slower rate. If polymerization occurs at a slower rate in a continuous vat polymerization process while the rate of pull remains constant, then the gel point will be higher because it takes more time for a given voxel to absorb the necessary amount of radiation to begin gelling. Changing the rate of draw for the print will change the Pre-Gelation Zone thickness in the same directions. Changing the intensity of the radiation will inversely proportionally change the Pre-Gelation Zone thickness. [0069] The Pre-Gelation Zone can be measured in several different ways. Optically as camera can see the interface from the side as the print is occurring. It can also be measure through X-ray tomography. It can also be correlated through the force between the part and the interface. [0070] The final cure on printer is separate from the Pre-Gelation Zone depth. The only constraint is that the final cure on printer must be higher than the cure % needed to get to the gel point. The exact percentage is dependent on the oligomers and monomers in the resin. In an embodiment, a final cure on printer % is 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 99%, or 100% depending on the desired final product and any post-processing needs. [0071] The Pre-Gelation Zone thickness is typically not the same throughout the cross section in the x-y direction of printing part. This could occur because the resin travels from outside of the part cure area where the bulk resin flows into and through the radiation area entering a first edge of the printing part to both the center and the second further edge of the part. With an even radiation across the cross section, one would expect that the center of the Pre-Gelation Zone could have a lower thickness than the edges of the part. This is because the Pre-Gelation Zone thickness comes from a cumulative dosage to the voxel of resin enables it to cure to the solid body. This difference can be more pronounced at the first edge. This Gel Point boundary can be made flat or adjusted by changing the intensity of the radiation flux from the center to the edge of the part. One can also change the intensity to make the edge even higher than the center, which would lower the force on the interface and prevent interface from being disturbed or damaged. When the resin or the interface is moving such as the case is with HARP, the Pre-Gelation Zone thickness would have a directionality to it. Often coordinating with the cumulative dosage integrated over the flow path length. In the case of HARP with even intensity when the flow of the resin and oil are moving left to right is that the Pre-Gelation Zone thickness would be larger on the left side of the part and narrow on the right side of the part.

‐ 18 ‐ [0072] There are multiple different ways to measure the PGZT, which can be specified for particular measurements.. Referring to the -x-y cross section of the printing, one could measure the Pre-Gelation Zone thickness at different locations, for example, at the first edge of the printing part, the second edge, the center, at the location identified as having the greatest Pre-Gelation Zone thickness in the x-y cross section, and/or at the location identified as having the smallest Pre- Gelation Zone thickness in the x-y cross section. To locate the center of a curing part in the xy dimension, one can locate the pixels in the x-y direction at the center of radiation print width and measure the Pre-Gelation Zone thickness at the corresponding point in the z direction. One can also measure Pre-Gelation Zone thickness in regions in the x-y cross section. When looking at the cross section, one can measure Pre-Gelation Zone thickness as the average of the Pre-Gelation Zone thicknesses at two locations at opposite sides each one 1 mm, 2 mm or 3 mm from the center point. [0073] The Pre-Gelation Zone thickness can also be measured by determining the average of thicknesses in all locations along the body width except for the 1 mm of width on each of the outer edges of the body or by determining the average of thicknesses in all locations along the body width except for the 2 mm of width on each of the outer edges of the body. The Pre-Gelation Zone thickness can also be measured by determining the average of thicknesses in all locations along the body width except for portion within 1 mm of the center of the body or by determining the average of thicknesses in all locations along the body width except for portion within 2 mm of the center body. [0074] Embodiments of the present invention advantageously utilize higher Pre-Gelation Zone thicknesses. In some embodiments, Pre-Gelation Zone thickness measured at the first edge may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1000 microns, up to 1500 microns, up to 2000 microns, up to 2500 microns, up to 3000 microns, up to 4000 microns, or up to 5000 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the first edge of between 100 and 5000 microns, preferably between 100 and 4000 microns, preferably between 100 and 3000 microns, preferably between 100 and 2000 microns, more preferably between 100 and 1000 microns, more preferably between 200 and 800 microns, more preferably between 200 and 600 microns, or more preferably between 150 and 400 microns. In an aspect, this invention

‐ 19 ‐ provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the first edge of between 200 and 3000 microns, preferably between 200 and 2000 microns, preferably between 200 and 1000 microns, more preferably between 200 and 500 microns, more preferably between 200 and 400 microns, or more preferably between 200 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the first edge of between 300 and 3000 microns, preferably between 300 and 2000 microns, preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0075] In some embodiments, Pre-Gelation Zone thickness measured as the average of the Pre-Gelation Zone thicknesses of the first edge and the second edge may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least about 300 microns, at least up to 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1000 microns, up to 1500 microns, up to 2000 microns, up to 2500 microns, up to 3000 microns, up to 4000 microns, or up to 5000 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness measured as the average of the Pre- Gelation Zone thicknesses of the first edge and the second edge of between 100 and 3000 microns, more preferably between 100 and 2000 microns, more preferably between 100 and 1000 microns, more preferably between 100 and 500 microns, more preferably between 100 and 400 microns, or more preferably between 100 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness measured as the average of the Pre- Gelation Zone thicknesses of the first edge and the second edge of between 200 and 3000 microns, more preferably between 200 and 2000 microns, more preferably between 200 and 1000 microns, more preferably between 200 and 500 microns, more preferably between 200 and 400 microns, or more preferably between 200 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness measured as the average of the Pre- Gelation Zone thicknesses of the first edge and the second edge of between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns.

‐ 20 ‐ [0076] In some embodiments, Pre-Gelation Zone thickness measured at the center may be at least 50 microns, more preferably at least 100 microns, more preferably at least 200 microns, more preferably at least about 300 microns, preferably at least up to 400 microns, more preferably at least 500 microns, more preferably at least 600 microns, more preferably at least 800 microns, and up to 1000 microns, up to 1500 microns, up to 2000 microns, up to 2500 microns, up to 3000 microns, up to 4000 microns, or up to 5000 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the center of between 100 and 3000 microns, more preferably between 100 and 2000 microns, more preferably between 100 and 1000 microns, more preferably between 100 and 500 microns, more preferably between 100 and 400 microns, and more preferably between 100 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the center of between 200 and 3000 microns, more preferably between 200 and 2000 microns, more preferably between 200 and 1000 microns, more preferably between 200 and 500 microns, more preferably between 200 and 400 microns, and more preferably between 200 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the center of between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, and even more preferably between 250 and 350 microns. [0077] In some embodiments, Pre-Gelation Zone thickness at the location identified as having the greatest Pre-Gelation Zone thickness in the x-y cross section may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1000 microns, up to 1500 microns, up to 2000 microns, up to 2500 microns, up to 3000 microns, up to 4000 microns, or up to 5000 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the location identified as having the greatest Pre-Gelation Zone thickness in the x-y cross section of between 100 and 3000 microns, more preferably between 100 and 2000 microns, more preferably between 100 and 1000 microns, more preferably between 100 and 500 microns, more preferably between 100 and 400 microns, or more preferably between 100 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the location identified as having

‐ 21 ‐ the greatest Pre-Gelation Zone thickness in the x-y cross section of between 200 and 3000 microns, more preferably between 200 and 2000 microns, more preferably between 200 and 1000 microns, more preferably between 200 and 500 microns, more preferably between 200 and 400 microns, or more preferably between 200 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the location identified as having the greatest Pre-Gelation Zone thickness in the x-y cross section of between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0078] In some embodiments, Pre-Gelation Zone thickness is measured as the average of the Pre-Gelation Zone thicknesses of point located at opposite sides at a distance from the center of 1 mm, 2 mm, or 3 mm, or by determining the average of thicknesses in all locations along the body width except for the 1 mm of width on each of the outer edges of the body, or by determining the average of thicknesses in all locations along the body width except for the 2 mm of width on each of the outer edges of the body, or determining the average of thicknesses in all locations along the body width except for portion within 1 mm of the center of the body or by determining the average of thicknesses in all locations along the body width except for portion within 2 mm of the center body. In each of those instances, the PGZT may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1000 microns, up to 1500 microns, up to 2000 microns, up to 2500 microns, up to 3000 microns, up to 4000 microns, or up to 5000 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness measured as stated above in this paragraph of between 100 and 3000 microns, more preferably between 100 and 2000 microns, more preferably between 100 and 1000 microns, more preferably between 100 and 500 microns, more preferably between 100 and 400 microns, or more preferably between 100 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness measured as stated above in this paragraph of between 200 and 3000 microns, more preferably between 200 and 2000 microns, more preferably between 200 and 1000 microns, more preferably between 200 and 500 microns, more preferably between 200 and 400 microns, or more preferably between 200 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens

‐ 22 ‐ using a Pre-Gelation Zone thickness measured as stated above in this paragraph of between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0079] In some embodiments, Pre-Gelation Zone thickness at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section may be at least 50 microns, at least 100 microns, preferably at least 200 microns, more preferably at least 300 microns, at least 400 microns, at least 500 microns, at least 600 microns, or at least 800 microns, and up to 1000 microns, up to 1500 microns, up to 2000 microns, up to 2500 microns, up to 3000 microns, up to 4000 microns, or up to 5000 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section of between 100 and 3000 microns, more preferably between 100 and 2000 microns, more preferably between 100 and 1000 microns, more preferably between 100 and 500 microns, more preferably between 100 and 400 microns, or more preferably between 100 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section of between 200 and 3000 microns, more preferably between 200 and 2000 microns, more preferably between 200 and 1000 microns, more preferably between 200 and 500 microns, more preferably between 200 and 400 microns, or more preferably between 200 and 300 microns. In an aspect, this invention provides an additively manufactured optical lens using a Pre-Gelation Zone thickness at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section of between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0080] In other embodiments, Pre-Gelation Zone thickness at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section may be advantageously less than 200 microns, more preferably less than 150 microns, more preferably less than 100 microns, or particularly more preferably less than 50 microns, including 0 microns. [0081] For embodiments having such smaller Pre-Gelation Zone thicknesses at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section described

‐ 23 ‐ above, the additively manufactured optical lens uses a Pre-Gelation Zone thickness at the first edge of between 250 and 3000 microns, more preferably between 250 and 2000 microns, more preferably between 250 and 1000 microns, more preferably between 250 and 500 microns, more preferably between 250 and 400 microns, more preferably between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0082] For other embodiments having such smaller Pre-Gelation Zone thicknesses at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section described above, the additively manufactured optical lens uses a Pre-Gelation Zone thickness measured as an average of the thicknesses at the first edge and second edge of between 250 and 3000 microns, more preferably between 250 and 2000 microns, more preferably between 250 and 1000 microns, more preferably between 250 and 500 microns, more preferably between 250 and 400 microns, more preferably between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0083] For yet other embodiments having such smaller Pre-Gelation Zone thicknesses at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section described above, the additively manufactured optical lens uses a Pre-Gelation Zone thickness measured as an average of the thicknesses at the first edge and second edge of between 250 and 3000 microns, more preferably between 250 and 2000 microns, more preferably between 250 and 1000 microns, more preferably between 250 and 500 microns, more preferably between 250 and 400 microns, more preferably between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0084] For other embodiments having such smaller Pre-Gelation Zone thicknesses described above, the additively manufactured optical lens use a Pre-Gelation Zone thickness at the location identified as having the smallest Pre-Gelation Zone thickness in the x-y cross section of between 250 and 3000 microns, more preferably between 250 and 2000 microns, more preferably between

‐ 24 ‐ 250 and 1000 microns, more preferably between 250 and 500 microns, more preferably between 250 and 400 microns, more preferably between 300 and 3000 microns, more preferably between 300 and 2000 microns, more preferably between 300 and 1000 microns, more preferably between 300 and 500 microns, more preferably between 300 and 400 microns, or even more preferably between 250 and 350 microns. [0085] The Pre-Gelation Zone thickness may only be applicable to the internal region of the part and once it is able to reach a steady state. There is a start-up and shut down period of a print where this may not apply. This can be defined as a full set of slices of the part or looked at on a voxel-by-voxel basis looking at the individual stakes. Thus, for methods using any of the Pre- Gelation Zone thicknesses described above, the starting and ending part of the printing process will typically not utilize such Pre-Gelation Zone thicknesses throughout, but typically will having transitioning thicknesses. At the start of the process, the thickness grows to the Pre-Gelation Zone thicknesses described above. At the end of the process, the thickness decreases from the Pre- Gelation Zone thicknesses described above. For aspects of the inventions herein, the printing process utilizes the greater thicknesses described in the paragraphs above for at least 50.0% of the print time for a lens, and preferably 60.0%, more preferably 70.0%, more preferably 80.0%, more preferably 90.0%, or more preferably 95.0%. For aspects of the inventions herein, the printing process utilizes the greater thicknesses described in the paragraphs above for between 60.0% and 99% of the print time for a lens, between 70.0% and 99% of the print time for a lens, between 80.0% and 99% of the print time for a lens, between 90.0% and 99% of the print time for a lens, or between 95.0% and 99% of the print time for a lens. For aspects of the inventions herein, the printing process utilizes the greater thicknesses described in the paragraphs above for between 60.0% and 95% of the print time for a lens, between 70.0% and 95% of the print time for a lens, between 80.0% and 95% of the print time for a lens, or between 90.0% and 95% of the print time for a lens. [0086] For aspects of the inventions herein, the printing process utilizes the greater thicknesses described in the paragraphs above for the internal region of the Body B at least one Pre-Gelation Zone thickness from the edge of the lens, and preferably at least two Pre-Gelation Zone thicknesses from the edge of the lens, more preferably at least 3 pre-gelation zone thicknesses from the edge of the lens more preferably at least 4 pre-gelation zone thicknesses from the edge of the lens, or at least 5 pre-gelation zone thicknesses from the edge of the lens.

‐ 25 ‐ [0087] If there are multiple parts on a print, they can be treated as separate parts with separate Pre-Gelation Zones, so having a lens and a frame printing at the same time, only the section with the optic portion of the lens needs to have the Pre-Gelation Zone large enough while the frame section or any non-optically active section of the final part can have a smaller (or larger) Pre- Gelation Zone that is found for not optics components. It also can have the same zone to simplify the calculations for the user. In a similar note, the setting for the supports can be different. They can even be printed layer by layer and then the print transitions to continuous once it gets the optically relevant part of the lens. [0088] Continuous Vat Polymerization provides a method for additively manufacturing articles without layer lines resulting from layer-by-layer printing. By continuously pulling the article being manufactured while it is being polymerized, continuous vat polymerization techniques can create articles having a truly homogenous polymer network with the necessary level of precision. In terms of optical lens manufacturing, continuous vat polymerization provides a method for additively manufacturing optical lenses lacking the visual and optical imperfections present in optical lenses generated by traditional layer-by-layer techniques. Layer by layer printing utilizes a Pre-Gelation Zone depth of 0. It gels off the interface and grows the gel until it reaches the fully solidified body one layer height above the interface. This is fundamentally different from the embodiments set forth herein as the resin does not move while it is being cured. This creates differences at the top and bottom of each layer in terms of the final cure on printer percentage. [0089] An important part of the systems set forth herein is that the final cure on printer is sufficiently the same in the areas utilizing the print process and has gone past the hardening Pre- Gelation Zone. For aspects of the inventions herein, the variation of the final cure on printer in the area of interest described above is less than 40%, and preferably less than 30%, more preferably 20%, and more preferably less than 15%, and preferably less than 10%, more preferably 5%, and more preferably less than 3%, and even more preferably less than 1%. [0090] The homogeneity of an optical lens can be measured using optical metrology. In an example, a wavefront sensor is used to measure optical metrology. In an example, a Shack- Hartmann wavefront sensor is used. Making use of this sensor involves shining light through the lens onto a variety of lenslets. These lenslets measure the degree to which light hitting the lenslet is tilted. When these tilt measurements are combined, the overall degree of tilt of the wavefront

‐ 26 ‐ can be measured. An optimally homogenous network would have very little tilt due to the minimal presence of optical aberrations. [0091] In an aspect, the present invention provides an optical lens having a homogenous polymer network comprising a directional component. In an aspect, the present invention provides an optical component precursor having a homogenous polymer network comprising a directional component. For the purposes of this invention, a directional component is defined as an overall order of polymerization of the components of the resin formulation in the direction of pull during the additive manufacturing process. The presence of mono-, di-, tri-, and tetrafunctional aromatic rings in the resin formulation contributes to this overall order. The di- and tri-functional aromatic rings align in the direction of pull providing a directional component while the mono- and tetrafunctional rings do not align in the direction of pull, providing disorder in all directions. This combination provides an overall order of the polymerization in the direction of pull while also maintaining a homogenous network throughout the manufactured article. Further, the overall amount of directionality can be affected by the ratio of mono and tetrafunctional rings to the ratio of di and trifunctional rings. In an example, increasing the amount of monofunctional rings relative to the other rings in a resin formulation decreases the directionality of the final optical lens. [0092] This directionality is not available to traditional layer-by-layer techniques. Additionally, any directionality obtained from layer-by-layer stereolithography would be present perpendicular to the direction of pull because of this weak layer-to-layer cohesion resulting in a non-homogenous network. This technique is also not available to thermoset lens blanks manufactured using traditional casting techniques as those techniques involve a holding period wherein the resin is stationary as it is polymerizing allowing it to achieve maximum disorder. A directional aspect is the result of movement of the polymerizing resin as it is curing. Traditional casting and traditional layer-by-layer additive manufacturing techniques all involve the green product remaining stationary while resin cures, thus limiting the ability for these techniques to impart a directional aspect into the polymer network of the articles being manufactured. In an aspect, this directionality can be perceived as different directional properties when lenses are printed in different directions. For example, an additively manufactured lens of the present invention can have a directional component having a different index of refraction when light is shone through perpendicular different directions of the lens. In an example, this difference, referred to Δ index, here as the is at least 0.01, more preferably at least 0.02, more preferably at least 0.03,

‐ 27 ‐ more preferably at least 0.04, and more at least preferably 0.05. The Δ index of the lens can be as high as 0.10 or even 0.15. In an example, light shone through the lens refracts to a different degree than light shone through the lens perpendicular to the direction of print. Thus, the lens provided by this invention can have an index of refraction in one direction that differs from the index of refraction perpendicular to that direction. For example, an additively manufactured having a directional component has different tensile strength in different directions. [0093] The differences between the lens provided by this invention and the lenses produced using traditional techniques can be noted in the differences in mechanical properties imbued into a homogenous network by the directional aspect. In an aspect, this invention provides an optical lens that has a tensile strength that is at least 3.0% stronger in a directional aspect of a homogenous polymer network of the lens compared to perpendicular to directional aspect of the homogenous network, more preferably at least 5.0% stronger, more preferably at least 10% stronger, more preferably at least 15.0% stronger, more preferably at least 20.0% stronger, more preferably at least 25.0% stronger. In an aspect, this invention provides an optical lens that has at least 3.0% greater extension properties in a directional aspect of a homogenous polymer network of the lens compared to perpendicular to the directional aspect of the homogenous network, more preferably at least 5.0% greater extension properties, more preferably at least 10.0% greater extension properties, more preferably at least 15.0% greater extension properties, more preferably at least 20.0% greater extension properties, more preferably at least 25.0% greater extension properties, and up to 50.0% greater. [0094] In addition to the unique mechanical properties of an optical lens having a homogenous polymer network comprising a directional aspect, there are unique optical properties. In an aspect, this invention provides an optical lens having a homogenous polymer network with a directional aspect that has a Δ index of at least 0.01 when light is shone through the lens in the same direction as the directional aspect compared to when light is shone through the lens perpendicularly to the directional aspect, more preferably a Δ index of at least 0.02, more preferably a Δ index of at least 0.03, more preferably a Δ index of at least 0.04, more preferably a Δ index of at least 0.05, and up to 0.10 higher. [0095] In an aspect, the strength of the directional aspect, and thus mechanical and optical property difference of the lens in the directional aspect compared to perpendicular to the directional aspect, can be thought of as an overall amount of aromatic rings aligning in a direction. This means

‐ 28 ‐ that an optical lens constructed from a resin formulation having a higher total amount of di- and tri-functional aromatic rings will have a stronger directional aspect than an optical lens constructed from a resin formulation having a lower total number of di- and tri-functional aromatic rings, and thus, have a greater difference in mechanical and optical properties in the direction of the directional aspect compared to perpendicular to the directional aspect. Additionally, an optical lens constructed from a resin formulation having a given amount of aromatic rings with that given amount of aromatic rings having a greater percentage of di- and tri-functional aromatic rings as compared to mono- and tetra-functional aromatic rings will have a stronger directional aspect than an optical lens constructed from a resin formulation having the same amount of total aromatic rings, but a smaller percentage of di- and tri-functional aromatic rings as compared to mono- and tetra-functional aromatic rings. An optical lens having a homogenous polymer network with a directional aspect that affects the mechanical and optical properties of the lens is not available to traditional optical lens manufacturing or traditional additive manufacturing techniques. Through experimentation with a resin formulation, an appropriate number of aromatic rings and ratio of di- /tri-functional rings to mono-/tetra-functional rings can be determined that imbue a strong enough directional aspect without sacrificing the mechanical and optical properties in the lens perpendicular to the directional aspect. [0096] Despite the potential advantages of directionality within a lens, excessive directionality can cause optical or mechanical imperfections within an optical component, which in turn would affect performance. Within products having homogenous networks, there are degrees of homogeneity, and more homogeneity is achieved through a more relaxed network. A relaxed network also improves the consistency of the optical properties throughout the lens. When comparing two polymer networks, a network is more relaxed when the chains of the polymer network are not aligned in the same direction. This is due to the chains having achieved a lower energy state because chains in alignment apply stress to one another. Relaxed networks, on the other hand, have chains moving in all directions, which can relieve the stresses that chains in alignment apply to one another. When polymers are formed under force, a polymer network that formed more slowly achieves a more relaxed network than a polymer formed quickly. In continuous vat polymerization, a more relaxed network can be achieved by slowing the rate of pull in tandem with decreasing the reactivity of the resin. A continuous pull causes adhesion forces to act on the green body as it is pulling out of the resin. It also causes fresh resin to flow and replaces

‐ 29 ‐ the resin the polymerized onto the green body. This resin flow can push the polymer chains into the network, which can force chain alignment and prevent chains from achieving their lowest possible energy state. A slower rate of pull decreases the adhesive forces acting on the build plate as it pulls. It also decreases the speed of fresh, replacing resin flow. This, in turn, increases the amount of time that the fresh resin is exposed to the radiation. If the reactivity of the resin is also decreased by, for example, decreasing the amount of photoinitiators, then it will take longer for the resin to polymerize into the final network. This extra time allows for greater mobility of the polymer chains within the network as it is forming, which gives them a greater opportunity to find their lowest energy state. In an embodiment, this invention provides an optical lens produced by continuous vat polymerization that achieves a relaxed network. In an embodiment, this invention provides a method of continuous vat polymerization wherein the pull speed is coordinated with the reactivity of the resin to limit stress from chain alignment. [0097] In addition to the general mechanical benefits of directional aspect of the polymer network, it has a wide range of potential applications in optical lenses. One major potential application is lens polarization. Typical lens polarization is done by applying a coating to the lens or between two lenses. This coating is, for example, a vinyl coating having a network of polarizing molecules placed on it, such as hydrocarbons coated in crystals. The polarized agent network is aligned in a specific direction when it is assembled, typically through the use of running a charge through the film to align the polar molecules of the network. This network is aligned in a direction such that only light parallel to the direction of alignment of the network is able to pass through the lens. Typically, these coatings are applied to tinted glasses or sunglasses, and they limit the amount of glare, or light coming from a specific direction. Typical polarization filters have vertically aligned networks such that horizontal waves of light are blocked. This application limits the amount of glare one perceives when looking through the lens. Using the directionality provided by the continuous DLP vat polymerization process, polarization can be provided to an optical lens without the use of a coating. In an example, an additively manufactured optical lens or additively manufactured optical component precursor having a directionality further comprises a polarizing agent, the polarizing agent aligned with the directionality of the optical lens or optical component precursor. Suitable polarizing agents include, but are not limited to, tourmaline, iodine, silver, herapathite, crystal-coated hydrocarbons, and the like.

‐ 30 ‐ [0098] Another potential application is the use of liquid crystals. In optical material manufacturing, liquid crystals are typically utilized to alter the light transmission of the materials. They are a common polarizing agent in many different types of optical lenses, and they have additional potentially beneficial properties. Additionally, liquid crystals have been utilized to alter the strength of lenses. In order to achieve this, polar liquid crystals are suspended between two layers of light transmissive material. When an electric charge is administered to this liquid crystal layer, their orientation changes and the optical properties of the optical material change. Examples include standard LCD screens, smart windows that change the amount of light that pass through them, and liquid crystal lenses having a variety of benefits. One benefit of liquid crystals is their ability to change the strength of a lens. By aligning in certain orientations, the light that passes through the lens is either more dispersed or more converged, resulting in changes in the strength of the lens. The liquid crystals within the lens are capable of changing their orientation if a charge is placed through them in a given direction, which can cause changes to the curvature of the lens and thus changes to the sphere power. This is an option for a user that wants correction for both myopia and hyperopia, but does not want a lens having multiple sphere powers at any given time. In an example, a resin formulation for additive manufacturing of an optical lens includes a liquid crystal. The directionality within the network of an optical lens provided by a continuous vat polymerization process could align these liquid crystals in a direction within the lens itself allowing for the benefits of liquid crystal lenses without the need for additional processing steps to add them. [0099] In addition to this directionality and the general advantages of additive manufacturing, continuous vat polymerization has additional benefits to the field of optical lens manufacturing. One advantage is the wide array of material properties that continuous vat polymerization can provide. Typical vat polymerization manufacturing involves a post-print processing of the article after it comes off the printer but before the final product is achieved. This post-print processing of the article, also known as the “green” article when printing has completed but prior to completion of post-print processing, often involves further curing off of the printer. This additional curing can ensure that all the resin within the green product is completely polymerized and 100% cure is achieved. Often this curing involves both UV curing and thermal curing via a thermal initiator present in the initial resin formulation. Even though UV curing can occur during both the printing

‐ 31 ‐ process and the post-print processing, UV curing during post-print processing differs as it typically involves the use of a lamp administering UV light to only the surface of the green article. [0100] It has been found that altering the ratio of total curing that occurs during the printing process to curing that occurs in the post printing process can alter the material properties of the solidified resin. In an example, a given article printed using a given resin formulation that cures 50% during the printing process and 50% during the post-print processing will have different material properties compared the same article printed using the same resin formulation that cures 20% during the printing process and 80% during the post-print processing. This is due to the differences in the polymerization reactions that occur during the various stages of the printing process. Polymerization proliferates via either chain extension or cross-linking, and the different types of curing can provide for different ratios of chain extension to cross-linking in each article printed with a given resin formulation. These different ratios can result in significant mechanical property differences across a single article and/or across multiple articles printed with a given resin formulation. In an example, an article printed with a given resin formulation with a higher ratio of cross-linking to chain extension has greater mechanical hardness compared to an article printed from the same resin formulation with a lower ratio of cross-linking to chain extension. In an example, the lower degree of curing a given resin formulation undergoes on the printer as compared to after the printer, the greater the degree of crosslinking present in the polymer network of the solidified resin in the final article. In an example, an article printed with a given resin formulation with a higher ratio of cross-linking to chain extension has a more relaxed polymer network than a polymer formed from the resin formulation with a higher ratio of chain extension to cross-linking. [0101] Multiple aspects of the additive manufacturing process can be altered in order to alter the cure percentages at different stages of the manufacturing process. Example aspects include, but are not limited to, light intensity, temperature of thermal cure, print speed, amount of photo and/or thermal initiator present in the resin formulation, time exposed to light and/or heat during post-processing, temperature control during the printing process, among others. Through experimentation with a given resin formulation, articles having a wide variety of mechanical properties can be manufactured by altering these aspects of a continuous vat polymerization additive manufacturing process. Additionally, a given article undergoing a given print process can have different mechanical properties at different points in its geometry. During a printing process,

‐ 32 ‐ a 3D pixel, known as a voxel, of resin must receive a certain amount of energy in order to polymerize completely. This polymerization takes the form of either chain extension or cross- linking, with chain extension tending to impart more elastomeric material properties and cross- linking tending to impart more rigid material properties. Across voxels of an article, the amount of chain extension and cross-linking can be altered, thus imparting different mechanical properties across a single piece article from a single additive manufacturing process. [0102] Altering ratios of chain extension to cross linking as a method of mechanical property control is not available to layer-by-layer techniques. Layer-by-layer techniques lead to non- homogenous properties in articles as curing is stronger at the bottom of each layer compared to the top. Additionally, articles manufactured using layer-by-layer techniques have weak layer-to-layer connectivity, and thus the network is not homogenous. In order to properly alter mechanical properties via cure ratios and changes in the printing process, a true homogenous network is required. Additionally, proper control of cure ratios requires some measure of temperature control during the printing process. A significantly higher amount of control over these ratios is available to resin formulations comprising thermal initiators. Articles printed using these resins undergo additional thermal curing after the printing process is complete. In an example, thermal curing triggers significantly more crosslinking for an article printed using given resin formulation compared to an article cured using only radiation. The exothermic polymerization reactions occurring during the printing process can release enough heat to trigger this thermal curing, which can alter the network of the polymerizing resin. Continuous vat polymerization techniques having a temperature control mechanism, such as HARP, are uniquely suited to be able to create a homogenous polymerization network and better control cure ratios, allowing for them to have significantly more control over the polymerization network, and thus the properties of the final product, compared to other techniques. [0103] In the field of optical lens manufacturing, this ability to control the polymerization network can have unique benefits. In traditional optical lens manufacturing, a given material has given optical properties, and material selection must be made based on the properties of the desired lens. As a result, optical lens manufacturers must have access to multiple different materials to produce lenses for a wide variety of users. Manufacturing optical lenses using continuous vat polymerization, on the other hand, is capable of producing optical lenses having a variety of optical properties using a few resin formulations.

‐ 33 ‐ Method of making a lens that corrects for both lower and higher order aberrations [0104] Certain embodiments show an increase in Abbe Number through geometry over the sheet of the material set to an ASTM specification. [0105] In certain embodiments, two lenses may have the same spherical and cylindrical power, where that power is derived from the same inner and outer curve powers as well as the same diameter and center thickness. With all of those factors being equal, the lenses made from additive manufacturing according to the embodiments set forth herein that are designed to remove higher order aberrations will have a higher order than a lens made with traditional manufacturer methods. [0106] There are two sets of aberrations that cannot be solved by current manufacturing. Current manufacturing cannot provide, to certain thresholds, high quality surface texture and resolution while maintaining a smoothness required for an optical surface. [0107] The first of the aberrations is the dispersion that is a property of the material – this property of the material plus geometry provides the Abbe Number. The second is the non- uniformity of the sensor itself. Designing for both gives a more accurate part image to the sensor (in the case of opthalmics, such a design relates to the geometry of the eyeball). [0108] In an example, altering the ratio of chain extension to cross-linking ratio in the homogenous network of an additively manufactured optical lens using a given resin formulation will change the index of refraction of the final optical lens. In an example, altering the ratio of chain extension to cross-linking in the homogenous network of an additively manufactured optical lens using a given resin formulation will change the Abbe Number of the final optical lens. In an example, polymer networks having a higher ratio of cross-linking to chain extension can have a higher index of refraction as a result of the increase in cross-linked polymers refracting light to a greater degree than lower amounts of cross-linked polymers. Additionally, different regions of the lens can undergo different cure ratios, thus achieving differing optical properties throughout a single lens. In an example, an additively manufactured lens is formed using continuous vat polymerization having a non-uniform index of refraction. In an example, the optical lens is a bifocal lens, wherein the index of refraction and Abbe Number on the bottom of the lens differs from the index of refraction and Abbe Number on the top of the lens. In an example, the optical lens is a progressive lens, wherein the index of refraction and Abbe Number are varied throughout the lens to achieve differing sphere powers at different regions of the lens. This can be done by

‐ 34 ‐ having varying ratios of chain extension to cross-linking throughout the lens thus altering the optical properties of the lens at given points. OPTICAL LENS PRECURSORS [0109] In the context of lens geometry, lenses must have the necessary shape to provide correction and be able to fit into the desired frames.3D printing is capable of manufacturing optical lens precursors that are the same or substantially like the desired final shape of the lens. This differs from traditional techniques, where the lens blank typically needs to have a radius that is twice that of the radius between the final lenses’ optical axis and the edge of the lens. Additionally, lens blanks are perfectly circular and thicker than the final optical lens to allow the blank to be shaped to fit the selected frame. The result is that the volume of material used for a lens blank is more than double that of the volume of material present in the final optical lens. In an embodiment, this invention provides an optical lens precursor that uses less than double the volume of material present in the final desired optical lens. In an example, a 3D printed optical lens precursor uses less than 60.0% more volume of material than the desired final optical lens, or less than 50.0% more material, or less than 40.0% more material, less than 30.0% more material, less than 20.0% more material, less than 15.0% more material, less than 10.0% more material, less than 5.0% more material, less than 4.0% more material, less than 3.0% more material, 2.0% less than more material, 1.0%, or less than 0.5% more material. In other embodiments, a 3D printed optical lens precursor uses between 1.0% and 50.0% more volume of material than the desired final optical lens, or between 3.0% and 50.0%, between 4.0% and 50.0%, between 4.0% and 40.0%, between 5.0% and 40.0%, between 5.0% and 30.0%, between 10.0% and 50.0%, between 10.0% and 40.0%, between 20.0% and 50.0%, between 20.0% and 40.0%, In an embodiment, an optical component precursor uses substantially the same volume of material as the final desired optical lens. [0110] An additional benefit of using additive manufacturing is that optical lens precursors can also be printed smaller than the desired optical lens. This would allow for the optical lens precursor to be coated with an index match material to achieve the desired final dimensions, thickness, and smoothness. In an example, a 3D printed optical lens precursor is at least 5.0% smaller than the desired final optical lens, at least 4.0% smaller than the desired final optical lens, at least 3.0% smaller than the desired final optical lens, at least 2.0% smaller than the desired final optical lens, at least 1.0% smaller than the desired final optical lens, at least 0.5% smaller than the desired final optical lens, at least 0.1% smaller than the desired final optical lens, 0.01% smaller

‐ 35 ‐ than the desired final optical lens, at least 0.001% smaller than the desired final optical lens. An example optical lens precursor is considered to be substantially the same size as the final desired optical lens when its volume is within 90.0%-110.0% of the final desired volume of the optical lens more preferably within 95.0%-105.0% more preferably within 97.0%-103.0%, more preferably within 98.0%-102.0%, more preferably within 99%-101%. This allows 3D printed optical lenses to produce significantly less waste compared to traditional lens manufacturing using lens blanks and processing time to be reduced. In an aspect, this invention provides an additively manufactured optical component precursor comprising an optical lens precursor that is substantially the same size as the desired final optical lens. [0111] Printing optical lens precursors customized to individual users and as close to the desired geometry as the desired final optical lens becomes more important as decentration occurs. Decentration occurs when the user’s pupillary distance (PD), or the distance between the user’s pupils, differs from the frame’s pupillary distance (FPD), or the distance between the mechanical axes of the lenses in the frames. This causes a need to differentiate between the optical and mechanical axes of the lens during manufacturing. When decentration is accounted for using traditional manufacturing of lens blank technology, the lens blank used needs to be double the difference of the PD and the distance of frame center. For example, if the difference between a user’s PD and the distance of the center of their desired frame is 2 mm, then the smallest possible lens blank needs to be at least 4 mm larger than if there was no difference between PD and distance of frame center.3D printed optical lens precursors, on the other hand, do not have to increase the size when decentration occurs. Instead, the decentration can be considered and the portion of the optical lens precursor that will be the optical axis of the final optical lens can be moved when generating the CAD of the optical lens precursor to be printed, resulting in no necessary increases in size of the optical lens precursor. This further reduces time spent and waste produced during the processing of the optical lens precursor. PRODUCTS [0112] In addition to improvements on general optical lenses and the optical lens manufacturing process, continuous vat polymerization is capable of developing unique products not otherwise available to traditional optical lens or stereolithographic manufacturing techniques. In an aspect, this invention provides the capability for the additive manufacturing of frames and lenses simultaneously. In an aspect, a method making use of this invention is capable of printing

‐ 36 ‐ an optical lens precursor and/or an optical component precursor simultaneously with the associated frames. In an example, a single resin formulation is used to form both the optical lens precursor and/or optical component precursor and the associated frames. In an example, a suitable 3D printer is capable of holding at least two independent resin formulations with one being used for the optical lens precursor and/or optical component precursor and another being used for the associated frames. In an example, this is accomplished through a resin vat having separate compartments for different resin formulations. In an example, a suitable 3D printer comprises an attachment capable of being placed in the resin vat that can keep two resin formulations separate. The two lenses are made together as a single piece [0113] In certain contexts, prescriptions for each of a patient’s eyes may be different. In addition, each eye center may include a distance relative to the center line of the piece/or the centerline of the face with respect to the other eye center. [0114] The lenses have connections to which the sides of the frame’s hardware attach. [0115] In general, visors, goggles, and gas masks may be formed, according to the embodiments, to accommodate different prescriptions for each eye as well as different eye centers. Such embodiments are described in more detail below (see, e.g., paras.75-82 below). [0116] In an aspect, this invention provides a single additively manufactured optical component wherein said optical component further comprises at least two optical lens precursors. In an aspect, this invention provides an additively manufactured eyeglasses article manufactured as a single piece using a single resin formulation. In an aspect, an additively manufactured eyeglasses article further comprises at least one optical lens precursor and an associated frame. In an embodiment, both the optical lens precursors and the associated frame are printed from a single resin formulation. In an embodiment, the optical lens precursor and the associated frames have different ratios of cross-linking to chain extension in their polymer networks allowing for the frames and lenses to have different mechanical properties despite being constructed from the same resin formulation. In an embodiment, the optical center of at least one of the lenses differs from geometric center of the associated frame. In an embodiment, the optical lens precursors have different powers. This would be accomplished by exposing the optical lens precursor and the frames to differing amounts of energy during the printing process, which will affect the percentage of cure that occurs on the printer and thus the ratio of cross-linking to chain extension. In an embodiment, the frame of the additively manufactured eyeglasses article further comprises one or

‐ 37 ‐ more rims in fluid communication with the edges of the optical lens precursors and an adjoining piece between the optical lens precursors. In an embodiment, the adjoining piece further comprises one or more bridge regions connecting the rims surrounding the optical lens precursors designed to rest on the bridge of the nose when the frames are worn. In an embodiment, the frame of the additively manufactured eyeglasses article further comprises two or more end pieces, the two or more end pieces integral with the rims extending away from the center of the eyeglasses article. In an embodiment, the two or more end pieces each further comprise a hinge. In an embodiment, the hinge is removably couplable with an arm piece extending away from the eyeglasses article. In an embodiment, the hinge is capable of moving the arm piece up to 90 degrees. In an embodiment, the hinge is capable of moving the arm piece up to 120 degrees. In an embodiment, the additively manufactured eyeglasses article further comprises an arm piece integrally formed with the hinge during the additive manufacturing process. In an embodiment, the additively manufactured eyeglasses article comprises an arm piece integrally formed with an end piece without need for a hinge. In an aspect, this invention provides a fully formed eyeglasses article comprising frames and optical lens precursors additively manufactured as a single piece article. In an embodiment, a frame further comprises a coupling agent. In an embodiment, an additively manufactured eyeglasses article further comprises an outer frame component coupled to the frame via the coupling agent. A coupling agent present in the frame would allow the frame to be adhered to an outer frame component. This coupling agent would allow the additively manufactured frame to couple to a second frame piece via a coupling agent. This would allow for the additively manufactured frames to overcome aesthetic issues (i.e., color) that could arise from being constructed from the same resin formulation as the lenses. Additionally, this would allow for even greater customization of the frames by the end user by way of having multiple colors of the outer frame component that could be easily coupled to and uncoupled from the additively manufactured eyeglasses. Suitable coupling agents include, but are not limited to, magnets, latches, hinges, and the like. [0117] This invention would allow for the production of fully functioning eyeglasses using a single additive manufacturing process, which has numerous benefits including full customization for the end user in terms of both the optical lenses and frames, reduction of waste, decrease in necessary processing and fitting of lenses within the frames, and a decrease in the inventory needed on hand to make eyeglasses to order. Additionally, this invention would allow for the production

‐ 38 ‐ of eyeglasses less any structural feature of the frames, allowing for frame components to be fitted in at any later stage of production. This would include printing optical lens precursors and rims allowing for customization of bridges, end pieces, hinges, arm pieces, other components of eyeglasses, or any combination thereof. [0118] In an aspect, this invention provides an additively manufactured progressive optical lens having varying sphere and cylinder power throughout. Progressive optical lenses are defined as no line multi-focal lenses, which means that they are optical lenses having varying sphere powers throughout the lens. Typically, these lenses have 2 or 3 regions having different sphere powers from one another allowing correction of multiple acuity problems using a single lens. The typical shape of the sphere power of a progressive lens is an hourglass shape with the top of the lens having a negative sphere power to correct for myopia, an intermediate region, or progressive corridor, in the middle having varying sphere power that becomes more positive the further down the lens, and the bottom of the lens having a positive sphere power to correct for hyperopia. Progressive lenses also have a “blending region” that comes from both peripherals of the lens. This blending region allows the users vision to gradually adjust as the eye moves from the top of the lens, through the corridor, and to the bottom part of the lens, or vice versa. This is done through the use of different levels of cylinder power, the power becoming more positive as the blending region approaches the bottom of the lens. This cylinder power is necessary to remove distinct lines of corrective changes in the lens; however, the varying cylinder power often causes a blurry astigmatism style visual aberration as cylindrical curvature causes the image to focus on a plane rather than a point as is the case with spherical lenses. This is true in cases where the cylinder power is both too strong and too weak for the user’s corrective needs. Increasing the size of the blending region can allow for less of this blurring as the cylinder powers can be weaker, but this comes at the cost of decreasing the size of the top and/or bottom regions of the lens. Alternatively, the size of the top and/or bottom regions of the lens can be increased with the resulting lens having stronger cylinder power in the blending region and thus increased blurriness. [0119] In an embodiment, a progressive lens can be achieved through manufacturing of one or both curves separately from the lens itself. In an embodiment, a progressive lens is formed by additively manufacturing a curve structure directly onto a pre-formed lens. Additive manufacturing is uniquely positioned to transform generic, pre-formed lenses into progressive lenses by manufacturing only the unique curvature that makes the lens progressive and affixing that curve

‐ 39 ‐ to a preformed lens. In an embodiment, an additively manufactured progressive curve is affixed to a pre-formed lens during a 3D printing process. In an embodiment, an additively manufactured progressive curve is affixed to a pre-formed lens during post-processing. [0120] Using traditional optical lens manufacturing techniques, lens blanks are generated having a variable sphere power on one curve, and then the other curve is shaped to accommodate for a specific user’s corrective needs. With this technique, it is difficult to truly customize a lens to a user’s corrective needs and can limit the availability to freely customize lens power, lens fit, material, and frames. This can result in visual acuity compromises particularly on the peripheral of the lens and for users with astigmatism. This becomes a more significant issue as decentration occurs, which limits the selection of frames that can be used with progressive lenses. Additionally, free form shaping techniques have been developed that can customize both the front and back of a progressive lens to more effectively fully customize a user’s eyewear and increase their visual acuity; however, these lenses are expensive to produce and take significantly more time than only shaping one side of the lens. Additive manufacturing is capable of producing progressive lenses in the same way that they would produce any other lens with the full spectrum of customization of the different aspects of the lens available. All of the different aspects of the progressive lens can be customized to meet a user’s specific needs. This can be accomplished by directly printing an optical lens precursor of a progressive lens from a CAD of the desired lens, thus removing extra manufacturing steps, and allowing full customization of the lens. [0121] In an aspect, this invention provides an additively manufactured wrap around optical lenses. In an aspect, this invention provides an additively manufactured wrap around optical lens precursor. Wrap around lenses are desired for additional protection as compared to traditional eyeglasses, and they provide protection against light and debris towards the outside of the eye. Typically, wraparound lenses are useful for eyeglasses meant to be worn during active periods or as protection for users suffering from eye-related conditions. Non-limiting examples include wrap around sunglasses, motorcycle glasses, and athletic eyewear (goggles, protective and/or corrective lenses worn during athletics etc.). Current manufacturing techniques of wraparound lenses are limited in terms of sphere power. The additional curvature necessary to provide the protection of wraparound lenses also limits the sphere power capabilities of these lenses. Typical wraparound lenses have a sphere power range between -6.00 and +4.00. Additionally, typical wraparound lenses have a cylindrical power of -2.00 to +2.00. Users with prescriptions falling outside either

‐ 40 ‐ range struggle adjusting to wraparound lenses made using traditional optical lens manufacturing techniques. This is due to the lens blank selection based on the frames and not the ophthalmic prescription of the user. The desired frames are selected, and then the lens blank is selected based on the curvature of the frames. This limitation prevents traditional optical lens manufacturing using lens blanks to be able to correct high strength prescriptions in wraparound lenses. [0122] Continuous vat polymerization techniques can allow for the manufacture of wraparound lenses that overcome this limitation as optical lens precursors can be manufactured that both meet the curvature requirements of the frames and the corrective requirements of the user. In an aspect, this invention provides additively manufactured wraparound optical lenses. In an aspect, this invention provides an additively manufactured wraparound optical lens having a sphere power outside the range of traditional optical lens manufacturing techniques. [0123] In an aspect, this invention provides an additively manufactured optical component precursor, wherein the optical component precursor comprises a single piece optical region, the single piece optical region spanning a distance sufficient to provide optical capabilities across both of a user’s eyes. In an aspect, this invention provides an optical component precursor comprising a single piece having two independent optical regions. Similarly to wraparound lenses, traditional optical lens manufacturing techniques have limitations in making single piece optical lenses spanning both eyes. This type of optical lens plays a key role in protective eyewear. Non-limiting examples of this type of lens include, but are not limited to, ski goggles, lab goggles, and gas masks. In order to effectively manufacture these optical lenses using traditional techniques, blanks must be made specifically to fit the shape of the frame of these lenses, which often have very unique geometries specific to their functionality. Additive manufacturing is capable of accommodating these unique geometries using the same techniques they would use to manufacture any other optical lens. Printing onto a part [0124] The embodiments provide methods for additively manufacturing onto another product. Such embodiments are only available to liquid interface printing because such printing enables a part to be dipped into the interface in order to allow for formation around the part. Further embodiments may accrue benefits from arrangements having multiple projectors. Such arrangements preferably ensure an even distribution of intensity around the object.

‐ 41 ‐ [0125] Apparatus with the multiple projectors angling to the part may allow parts to be printed on wave guides, stock lenses, electronics, as well as enabling printed parts formed from a different material. Aspects of these embodiments are set forth in more detail in the paragraphs that immediately follow. [0126] In an aspect, this invention provides an additively manufactured optical lens comprising an electronic component. In an aspect, this invention provides an additively manufactured optical component precursor comprising an electronic component. In an embodiment, an electronic component is partially optically transparent. In an embodiment, the optically transparent electronic component further comprises at least one display capability. In an embodiment, the optically transparent electronic component further comprises at least one eye tracking capability. Additive manufacturing is uniquely positioned to manufacture optical lenses having an electronic component, often referred to as “smart glasses”. Typical smart glasses manufacturing requires an additional processing step in which the electronic component is added between two lenses or else is placed onto the surface of the lenses. Additive manufacturing techniques, on the other hand, can dispose or affix the electronic component on the build surface and print the optical lens around the electronic component using any suitable additive manufacturing technique. Additionally, methods of additive manufacturing with a cooling aspect, such as HARP technology, can more effectively account for the temperature changes that can occur during the printing process, which can mitigate temperature related changes to the electronic component. Further, the use of a liquid printing interface such as HARP allows for the electronic component to be dipped into the interface, which provides more manufacturing freedom around said electronic component than is available using a solid interface. In an embodiment, an electronic component comprises a Waveguide display. In an embodiment, an electronic component is an augmented reality display. In an embodiment, an electronic component is a virtual realty display. In embodiment, an optical lens having an electronic component is an ophthalmic lens. [0127] Continuous vat polymerization may have advantages in manufacturing optical components beyond eyeglasses. In an embodiment, this invention provides an additively manufactured high order lens. In an embodiment, an additively manufactured high order lens is substantially free of aberrations. Additive manufacturing is capable of removing high orders of monochromatic aberrations through microscopic alterations to the structure of the surface of a lens in order to correct for unwanted reflection or refraction of light. In an embodiment, an additively

‐ 42 ‐ manufactured high order lens is a telescopic lens. In an embodiment, an additively manufactured high order lens is a microscopic lens. In an embodiment, an additively manufactured lens is transparent to infrared radiation. METHODS OF CONTINUOUS VAT POLYMERIZATION [0128] In an aspect, this invention provides a method for producing an optical component via additive manufacturing. In an aspect, this invention provides a medium for controlling a continuous vat polymerization apparatus as it performs a method for forming an optical component. In an aspect, this invention provides a method for producing one or more optical component(s) via additive manufacturing. In an embodiment, a CAD is generated of the optical component based on optical data, and then an image stack is generated based on the CAD that will dictate how a radiation source will emit energy to selectively cure the resin formulation. Then, a resin formula suitable for optical lens manufacturing will be selected and disposed within a resin vat of a continuous vat polymerization 3D printer. Then, a radiation source will sequentially emit patterned energy into the resin in the vat to dictate the polymerization of the resin based on the images from the image stack while the solidified resin is continuously pulled away from the radiation source. This step will repeat itself until a green product of the optical component precursor has been formed. Then, the green product of the optical component precursor will undergo post-print processing including at least in an aspect further curing the green product off of the 3d printer until the green product has achieved 100% polymerization and an optical component has been formed. In an embodiment, an optical component further comprises at least one optical lens precursor. In an embodiment, an optical component further comprises at least one optical lens. Apparatus and part design of the supports for the Anti-Reflective (“AR”) coating system [0129] Some of the embodiments may include an adhesion zone support structure, see, e.g., FIGs.25-29, and portions of the specification corresponding thereto. [0130] Further embodiments may include a removably-couplable build stage with etched identifiers. Such etched identifiers may be used to identify the optical component during processing. Such an exemplary build stage may accompany the optical component through post- processing, including application of an AR coating. [0131] In some embodiments, optical components are adhered to the build stage via adhesion zone until post-processing is complete. Such an adhesion zone support structure may support the

‐ 43 ‐ optical component through spin coating and dip coating. Follow removal of the build plate and adjoined optical components from AR coating apparatus, the build plate and adjoined optical components can remained in a joined state during vapor coating. [0132] In certain embodiments, a solid wall support structure may be used. [0133] A solid wall support structure may include consistent geometry across multiple optical components thereby allowing it to be used as the base for any optical component design. A single solid wall support structure size may be sufficient to support both small and large lenses using the same solid wall support structure design. See, id. Such a solid wall support structure may be ideal for vapor coating as both faces are exposed to the vapor but an airtight seal is created between the faces by the solid wall. See, id. [0134] This involves the design of the support structure as well as the AR coating holders. In embodiments, the support structure may be changed to accept the lens with support. There are two conventional aspects of AR coating holders, one aspect involves a ring that directly touches the lens and another involves an array that holds all the rings – embodiments according to the invention can act to improve both aspects. See, id. [0135] In an embodiment, an optical component precursor further comprises a support structure, said support structure capable of supporting the optical lens precursor during at least one post-print processing step. In an embodiment, an optical component precursor further comprises at least one frame piece, said frame piece integrally formed with the optical lens precursor or optical lens. In an embodiment, the frame piece further comprises at least one rim, said rim integrally formed with and surrounding at least one of the optical lens precursor or optical lens. In an embodiment, the frame piece further comprises at least two optical lens precursors or optical lenses. In an embodiment, the frame piece further comprises an adjoining piece, the adjoining piece integrally formed with at least one rim. In an embodiment, the adjoining piece further comprises a nasal bridge. In an embodiment, the frame piece further comprises at least one end piece, said end piece integrally formed with at least one of the rims. In an embodiment, the frame piece further comprises at least one arm piece, said arm piece integrally formed with at least one end piece. In an embodiment, the at least one end piece further comprises a hinge. In an embodiment, the hinge is integrally formed with at least one arm piece. In an embodiment, the frame piece further comprises a coupling agent capable of attaching the frame piece to an outer frame component. In an embodiment, an image stack is generated directly from the optical data.

‐ 44 ‐ In an example, optical data further comprises a type of optical lens, an ophthalmic prescription defining at least one refraction component of the lens, the resin formulation to be used, the dimensions of optical lens, a frame shape, or combinations thereof. Radiation Sources [0136] Certain embodiments may remove aberrations caused by projectors. Such embodiments may involve Mie and Raleigh scattering, as described in more detail in para. 113. Certain embodiments may involve index matching the oil to ensure that there is no change in IR as the radiation passes from the interface into the resin, as described in more detail in para.112. [0137] Moving the part relative to the projector may also reduce or remove aberrations caused by projectors, as described in more detail in paras.104-105. Such movement may be implemented using a conveyor belt or other suitable mechanism. [0138] A collimating light source may also be used to reduce aberrations caused by a projector, as set forth in more detail in FIGs. 5 and 6 and the portions of the specification corresponding thereto. [0139] Other apparatus that may be used to reduce aberrations caused by the projector may include using multiple radiation sources in order to stop resin from overcuring when it leaves the resin vat. Such embodiments are described in more detail in exemplary para.100 and 101. [0140] On a similar note, a liquid that sits on the resin that either pushes the uncured resin off or is index matched to the cured part may be used to stop internal reflections. [0141] In an embodiment, continuous vat polymerization around an electronic component further comprises the use of multiple radiation sources. In an embodiment, the projection area of each radiation source surrounds the entire geometry of the electronic component. This ensures an even polymerization of material around the entirety of the electronic component. [0142] In addition to general continuous vat polymerization techniques, this invention provides specific techniques for the continuous vat polymerization of optical lenses and optical lens precursors. Specifically, the invention provides techniques for overcoming challenges specifically related to the continuous additive manufacturing of optical lenses. In an embodiment, the radiation source further comprises a DLP projector. DLP projectors make use of an array digital micromirrors devices (DMD) in order to be able to accurately project light in a pattern in order to precisely cure the resin into the desired 3D structure. In continuous vat polymerization, energy from DLP projector reflects off the array of DMD’s and into the resin formulation. The pattern is

‐ 45 ‐ determined by whether each mirror in the array is turned on or off, thus allowing control of the pattern of energy emitting from projector. A current limitation of DLP projectors used in 3D printing are the spaces between the DMD’s within the individual semiconductor chip of the projector. In an example DLP projector, these spaces are approximately up to 3 µm in length. In an example DLP projector, these spaces are approximately 1 µm in length with each mirror in the array having a pitch, or the distance from the center of one mirror to the center of an adjacent mirror, being approximately 5.4 µm in length. As the energy from the semiconductor chip passes through the lens of the DLP projector and expands outward, these microscopic spaces can lead to inconsistent degrees of solidification of the polymerizable resin and can result in stress bands on the surface of the additively manufactured article. These stress bands are imperceptive in most articles, but they can cause imperfections in refraction of light and perceivable aberrations in a lens. Microscopic spaces between DMD’s are exacerbated as the projection area of the radiation expands. In an example, a 3 micron gap between pixels becomes 5 microns in the projection area of the radiation. This expansion causes the radiation from the projector to reach the polymerizable resin at an outward angle. This can cause inconsistent curing as the center of the projection area receives increased radiation as compared to the edge, which results in stress bands that appear in areas that received greater amounts of radiation. [0143] Techniques exist that can overcome this limitation both in individual projectors and projector arrays. In an example, the DLP projector further comprises a rotational component, the rotational component allowing the DLP projector to freely rotate throughout the printing process. An example suitable rotational component would be a rotational actuator. Rotating the light projector throughout the printing process can more evenly distribute the energy from a given projector throughout the projection area of the projector, mitigating the effect of the gaps between the DMD’s. In an example, the DLP projector further comprises a vibratory component, which more evenly distributes the intensity of radiation across the projection area of the projector. [0144] In an embodiment, emitting sequential patterns of light from a DLP projector further comprises emitting sequential patterns of light from a DLP projector that is purposefully defocused. Purposeful defocusing, or “blurring” the projector can mitigate the effect of gaps between DMD’s. This blurring effect allows for crossover between the projection areas of the individual DMD’s, thus mitigating the effect of these gaps and effectively eliminating seam lines. As a result of this blurring, some amount of precision on the edges of the green product is lost,

‐ 46 ‐ which can result in roughness in the edges geometry of the green product; however, most green products and all optical lenses undergo some form of post-print polishing and/or edging, which can effectively eliminate this roughness. Blurring can be accomplished in a variety of ways. DLP projectors typically comprise at least one focusing lens, and they are calibrated to a specific focal distance based on the size and focus of the DMD’s within the projector. In an example, a DLP projector has a given pixel size, which generated by energy reflecting off the individual micromirrors with each micromirror independently contributing energy to one pixel. When the one or more focusing lenses are “in focus”, the pixel size is precisely what the optimal parameters of the projector designate. In an example, a projector suitable for 3D printing has an optimal pixel size of 72 microns. When the pixels have achieved the optimal size based on the parameters of the projector, the light from the projector has travelled a certain distance from the projector, which is the focal distance of the projector. By purposefully altering the focal point by moving the focusing lens, a DLP projector can be blurred, which means that the pixel size at a given focal point has changed. Typical alignment and focusing of projectors make use of a camera system that is a discrete distance from the projector. This camera can ensure that the optimal pixel size and focal distance are achieved when focusing the lens of the projector because of its discrete distance from the projector. In an embodiment, purposeful defocusing of the projector involves moving a camera a discrete distance towards or away from the projector, then adjusting the one or more focusing lens(es) of the projector so that the camera perceives the projector as “in focus”. This method allows for discrete “degrees of blurring” to be known and thus controlled. In an example, purposefully defocusing the projector such that the focal distance is greater than when it is in focus causes overlap of the radiation emitting from each micromirror in the DMD array. This method of purposeful defocusing would provide a controllable, measurable method to mitigate the negative effects of the spaces between the micromirrors because it allows for a meaningful change in pixel size without a meaningful change in the projection area. [0145] An additional method of purposeful defocusing is the use of X and Y-direction movement of the during the printing process in addition to Z-direction movement. In an embodiment, lateral movement of the product reduces the angle at which the radiation arrives at the polymerizable resin, which can eliminate the stress bands caused by outward expansion of the projection area. It also allows the product to be cured by multiple pixels within a projector or projector array, which ensures a more uniform application of radiation into the product. In an

‐ 47 ‐ embodiment, lateral movement of the 3D product comprises each voxel of the 3D product being cured by multiple pixels of one or more projectors as the 3D product is moved laterally. Suitable, non-limiting examples of methods for moving the product during manufacturing include a robotic arm and a conveyer belt. Apparatus for pulling out in a curve such that at the vertical center line of the lens, the normal of the curve (inside curve, outside curve, or the inside middle) is perpendicular to the interface. [0146] Certain embodiments may include a robotic arm, or other robotic device, attached to a build surface. Such a robotic device can move the build surface in preferably 360 degrees of freedom. A controller of such a robotic device may move in a curved motion that matches the curve of the lens being manufactured. Such an embodiment may ensure that a normal of the curve is perpendicular throughout the process. [0147] In an embodiment, a product is moved in a curve during a manufacturing process. The curved movement of the product could be used to help shape an optical component. Additionally, this limits the amount of under or overcure by allowing only the area undergoing polymerization to be in line with radiation. Overcure and undercure arise when radiation reaches beyond the interface of polymerization and into the green product that has been partially cured. In attempting or failing to account for radiation passing into the green product, over or undercure can occur, which prevents achieving the desired degree of polymerization from the printing process. A curved path of the green product would give greater control and specificity over the areas of the green product affected by radiation at any given time during the manufacturing process. In an embodiment, the normal of the curve of the lens remains perpendicular relative to the interface throughout the manufacturing process. [0148] In an embodiment, the product remains fixed in the X-direction, and instead the projector moves. [0149] Purposeful defocusing can also be accomplished using an array of projectors. In an embodiment, a radiation source further comprises a projector array. In an embodiment, the projection area of one of the projectors in the array is overlapped with another projector’s projection area by half a pixel. In doing so, the gaps between the DMD’s in each projector are accounted for by the other projector and intensity is distributed evenly throughout the combined projection area.

‐ 48 ‐ Apparatus for a hard mask collimated projection source [0150] In certain embodiments, micro actuators may be used to match the sdf file spacing and directly use that file for positional data . [0151] In an alternative embodiment, a DLP projector further comprises a hard mask. A hard mask is one that physically shapes the radiation from the projector by blocking all emission except for the desired shape. In an embodiment, a mask further comprises a controller, the controller dictating the movement of multiple linear actuators said linear actuators coupled to a bladder. In an embodiment, the number of linear actuators is equal to the number of dots in a dot array on an .sdf file. [0152] In an embodiment, linear actuators each match with a dot in the dot array. Each linear actuator achieves the depth in the x direction, which shapes the bladder to match the desired curve of the lens. Radiation then emits constantly, and the linear actuators move the bladder to maintain the shape of the dot array throughout the manufacturing process. [0153] Purposeful defocusing, or blurring, is not without its negative aspects. Blurring causes imprecise curing to occur at the perimeter of the 3D product. Blurring throughout a photopolymerization process would cause deformation and imperfect curing to occur at the outer edges of the projection area due to the blurring causing a lack of a solid edge to the projection area. In an embodiment, a method further comprises focusing and defocusing the projector purposefully throughout the additive manufacturing process. In an embodiment, a method further comprises using an additional radiation source. In an embodiment, an additional radiation source further comprises a laser. In an embodiment, a projector further comprises a collimating lens. In an embodiment, multiple collimating lenses are used at different heights. In an embodiment, a projector array makes use of one or more collimating lens such that the entire projection area of the array is collimated by the one or more collimating lens. In an embodiment, a projector having a collimating lens is positioned further from the interface than a projector that does not have a collimating lens. A collimating lens creates perfectly vertical pixel lines, which effectively eliminates the stress bands caused by outward angles of radiation from the projector. In an embodiment, the collimating lens moves laterally throughout the additive manufacturing process. [0154] Perfectly vertical pixel lines are also not ideal, however, because they create many, thin, vertical stress bands. An additional method of purposeful defocusing is the use of a light scattering agent in an interface between the radiation source and the resin. Any vat polymerization process

‐ 49 ‐ requires some material at an interface with the polymerizable resin. In an embodiment, a suitable 3D printing interface further comprises a light scattering agent. A light scattering agent at the interface would induce randomness into the radiation as it reaches the polymerizable resin. This would defocus the radiation at the interface, which can allow for the overlap of pixels and elimination of deficits caused by pixel gaps. Suitable light scattering agents include titanium dioxide. Manipulation of the type of scattering occurring involves altering the index of refraction of the interface material and the size and shape of the chosen scattering agent. In an embodiment, a scattering agent is chosen with a high index of refraction. In an example, an index of refraction of a suitable scattering agent is greater than 2, more preferably greater than 2.25, more preferably greater than 2.5, more preferably greater than 2.75. In an embodiment, an interface material is chosen that matches the index of refraction of the resin formulation, which would ensure consistent scattering throughout the vat. In an embodiment, an interface material is chosen with maximum light transparency, which would allow for the greatest level of control over light scattering. Elastic light scattering occurs when the scattered rays of light have the same wavelength as the incident rays. For a given light scattering agent, the angle of elastic scattering is inversely proportional to particle size. For a given light scattering agent, the amount of overall light scattered is directly proportional to particle size. These two factors determine the type of elastic scattering that will occur. Light scattering particles are categorized by a unitless size parameter, which is calculated using the formula: ^_{^ ൌ} ^{2 ^^ ^^} ^_^ where x the size parameter, r is the particle

λ is the wavelength of incident light. When this size parameter falls between 0.2 and 0.002, small particle scattering, or Rayleigh scattering, occurs. When this size parameter falls between 2000 and .02, Mie scattering occurs. Mie scattering occurs when the particle is substantially the same size as the wavelength of light. Optimal Mie scattering occurs when the size parameter is 1 (2πr = λ), which scatters light in all directions. Optimal Mie scattering may not be desired for certain applications of this invention because, although scattering in all directions within the projection area of the projector is desired to maximize disorder, additive manufacturing is most effective when most if not all the radiation to pass through the interface and enter the resin. Therefore, non-optimal Mie scattering is desired where the angle of scatter is relatively low to maximize the amount of radiation acting on the resin

‐ 50 ‐ within the projection area. In an embodiment, a method further comprises scattering the radiation from the radiation source at an interface, said interface in contact with the resin formulation, In an embodiment, this scattering comprises Mie scattering. [0155] In an embodiment, scattering is done by dispersing particles of a light scattering agent throughout the interface. In an embodiment, the size parameter of the particles is greater than 0.1, more preferably greater than 0.5, more preferably greater than 1, more preferably greater than 2. In an embodiment, a combination of Mie and Raleigh scattering is used. In an embodiment, the interface layer is index matched to the resin formulation. As an optical component is pulled away from a liquid interface, the interface pulls up slightly with the component. This can create a “lens” in the interface because a high index resin will cause light to refract to a much greater degree than a non-index matched resin, which in turn refracts the majority of the light intensity outward away from the center of the optical component. Index matching the interface to the resin ensures that there is no change in IR as the radiation passes from the interface into the resin. Software of reading the sdf file format and directly turning that into image stacks to go onto the software; [0156] In certain embodiments, pixel intensity and/or shape predistortion can happen to the image stack or as each image is made. CAD-Free printing of optical lenses is also possible, according to the invention, using dot arrays. [0157] Dot arrays are used to provide the shape of lenses during traditional manufacturing, and their 3D structures are saved as Signed Distance Field (.sdf) files. In an embodiment, this invention provides a medium capable of additively manufacturing a lens directly from an .sdf file. Such a medium may convert the .sdf file into an image stack by associating each layer of dots with a shape, and emitting patterned radiation based on that shape into the resin. [0158] In an embodiment, sequentially emitting patterned energy further comprises emitting energy having varying intensity. In an embodiment, generating an image stack further comprises determining a radiation intensity that each pixel of the images in the image stack will receive. A technique commonly referred to as “grayscaling” is known to additive manufacturers. Grayscaling refers to varying the intensity of energy emitted from the radiation source such that greater intensity is administered to some voxels resin than others. In traditional additive manufacturing techniques, grayscaling can increase the precision capabilities of the printer and ensure that each voxel of resin receives precisely the amount of energy desired to form the desired shape and

‐ 51 ‐ undergo the desired amount of polymerization. Grayscaling techniques can even allow for subpixel resolution thus allowing for more control over all aspects of the 3D printed part. Continuous vat polymerization techniques can obtain further benefits from grayscaling. The degree of polymerization of a given voxel of resin is directly proportional to the total amount of energy that voxel receives. Through the use of grayscaling, varying intensities of energy can be emitted into different voxels over a given period of time, thus, the different voxels receive different total amounts of energy and achieve different degrees of polymerization. Different types of polymerizations can be achieved during the printing process compared to post-print processing (i.e. chain extension vs. cross-linking), thus gray scaling can be used to alter the homogenous polymer network of an article manufactured using continuous vat polymerization. Gray scaling can also be used to mitigate the roughness caused by blurring. Suitable, non-limiting examples of Gray scaling techniques include algorithmic grayscaling, dithering grayscaling, or white noise grayscaling. [0159] In an embodiment, a radiation source is present within the resin vat outside of the pre- gelation zone. In an embodiment, the radiation source is an inhibiting radiation source. An inhibiting radiation source would facilitate the removal of excess resin affixing to the surface of the green product. In an embodiment, the radiation source can move throughout the resin vat during polymerization. In an embodiment, the radiation source is present in the build surface. In an embodiment, an inhibiting radiation source emits radiation at a different wavelength of light than the polymerizing radiation source. In an embodiment, an inhibiting radiation source is present on the build surface. This embodiment allows for inhibiting radiation to be shown directly into the part. In an embodiment, a resin vat further comprises a top liquid layer. In an embodiment, a top liquid layer is immiscible with the resin formulation. In an embodiment, the liquid layer Apparatus of the pre-gelation zone [0160] To maintain a pre-gelation zone according to the embodiments set forth herein, a truly continuous additive manufacturing (“AM”) machine may be needed. Continuous AM – constant pull throughout, may require some kind reduction in adhesive forces acting on the part. Suitable technology may include HARP, CLIP and any other vat polymerization printing processes. HARP operates through a mobile liquid interface that creates a shear stress beneath the emerging part and results in a slip boundary. https://www.science.org/doi/10.1126/science.aax1562

‐ 52 ‐ [0161] The slip boundary allows for the solidified part to be continuously retracted from the print interface. Fluorinated oils (perfluoropolyether copolymers, such as Solvay Fomblin Y or Chemours Krytox GPL) may be used for their omniphobic properties and higher densities relative to that of common SLA resins. CLIP oxygenates the area above the interface to inhibit curing (a dead zone). Thus, the Pre-Gelation Zone for such a CLIP system does not start at the interface, but instead starts just above the dead zone where polymerization begins to occur. In such a system, the Pre-Gelation Zone thickness is the distance in the z direction between the point where curing begins and the gel point boundary. Post-print processing of the optical lens component involves further curing of the optical component off of the printer. Additional post-print processing steps can be performed to ensure production of quality optical component, add customizable features, and alter the properties of the optical component. In an embodiment, post-print processing of the optical lens comprises a washing step, a spinning step, a coating step, a polishing step, a spraying step, a UV curing step, a thermal curing step, and combinations thereof. In an embodiment, an optical component comprises a support structure capable of supporting the optical component throughout at least one of these post-print processing steps. In an embodiment, a continuous vat polymerization 3D printer comprises a build surface onto which the optical component is polymerized. In an embodiment, this build surface is a removable build surface capable of supporting the optical component throughout at least one post-print processing step. In an embodiment, a support structure comprises an adhesion zone meant to affix the optical component to the removable build surface. [0162] All additively manufactured parts must undergo a washing step. This washing step ensures that all uncured resin present on the surface of the 3d printed part is removed. This washing step should be performed prior to any further curing to ensure that only the desired amount of solidified resin is present in the final product. In an example, a washing step further comprises soaking the green product in a liquid capable of removing excess resin from the part based on the resin formulation. Typical washing steps make use of 90-100% isopropyl alcohol (IPA), which is suitable for removal of most uncured resins. [0163] In addition to a washing step, a spinning step can be performed for further removal of additional resin. In an example, a spinning step involves rotating the green product at a speed capable of removing excess uncured resin from the green product. A spinning step can be done instead of or in addition to a washing step to ensure removal of excess resin. Optionally, heated air

‐ 53 ‐ blades can be used in addition to or as an alternative to spinning. In an embodiment, heated air blades are used while the green product is still within the additive manufacturing apparatus to remove excess resin from polymerized portions of the green product. [0164] Once excess resin has been removed, further processing of the optical component can occur. In an embodiment, once excess resin has been removed, a coating step is performed. A coating step involves placing a thin film on the surface of the part, which can provide beneficial properties and remove minor imperfections in the part’s surface. In an embodiment, a coating step comprises coating the optical component in an index match material. This index match material would fill in any microscopic imperfections and not alter the optical properties of the optical component because the index of refraction is the same as the optical lens precursor. In an embodiment, the index match material is the resin formulation used to print the optical component with an added viscosity-increasing agent to ensure that the part is sufficiently coated. In an embodiment, the index match material further comprises anti-abrasive properties, anti-reflective properties, light absorbing properties, a polarized component, or combinations thereof. Most lenses produced using any manufacturing method undergo coating treatments to grant the lens beneficial properties. Suitable coating techniques include, but are not limited to, dip coating, spin coating, or vapor coating. In an embodiment, a coating step for an optical component comprising an optical lens precursor comprises only applying a coating to the optical lens precursor. In an embodiment, a coating step comprises applying a coating to the entire optical component including an optical lens precursor and any other components. In an embodiment, a coating step further comprises a hard coating step. In an embodiment, a hard coating step comprises using any suitable coating technique to specifically apply an anti-abrasive coating to the optical component. In an embodiment, both an optical lens precursor and a frame undergo a hard coating step. [0165] In an embodiment, once excess resin has been removed, a polishing step is performed. For general additive manufacturing purposes, a polishing step is performed to ensure a smooth surface of the 3d printed part. This typically takes the form of sanding the part before or after a coating has been applied. For optical lens manufacturing, polishing provides a key step to ensure optical clarity. Additionally, polishing of an optical component comprising an optical lens precursor can further shape the geometry and curvature of the lens to ensure that it both fits into the frames and has the appropriate visual correction properties. An optical component may undergo a polishing step prior to or after a coating step. In an example, the polishing step is a chemical

‐ 54 ‐ mechanical polishing step which makes use of mechanical polishing and a chemical slurry that is able to effectively remove imperfections and ensure that the dimensions of the optical component are maintained. [0166] Further curing of a green product off of the printer is a key component of post-print processing of a green product. Solidified resin in the green product has polymerized to the point where it can hold a solid structure; however, the green product has not achieved 100% polymerization throughout. In most cases, this is done purposefully to allow for further types of curing to occur off of the printer, which can induce certain mechanical properties in the part. In an embodiment, post-print curing further comprises further UV curing. In an embodiment, UV curing comprises exposing the green product to a UV lamp. This curing facilitates further polymerization of the green product on the surface of the part. In an embodiment, post-print curing further comprises thermal curing. In an embodiment, thermal curing occurs at a temperature higher than the temperature at which a thermal initiator decomposes to initiate polymerization but lower than the heat deflection temperature of the optical component. In an embodiment, post-print curing further comprises a combination of UV and thermal curing. In an embodiment, a combination of UV and thermal curing comprises using the combination of UV and thermal curing to induce a desired ratio of cross-linking to chain extension in the final product. In an embodiment, thermal curing is used to increase the disorder of the polymer network when Silicon groups are present in the resin formulation. In an embodiment, a thermal curing step increases the energy of the polymer network and breaks non-covalent thiol-thiol interactions and causes thiols to interact with aromatic rings. The additional thermal energy changes the free energy of the network and allows it to achieve more disorder than in the absence of thermal curing. [0167] In an embodiment, post-print processing further comprises a spraying step. In an embodiment, this spraying step can apply a surface coating to an optical component. This spraying step is particularly useful when the optical component comprises a frame. The spraying step can apply a color coating to the frames while maintaining the optical clarity of the optical lenses or optical lens precursors. [0168] In an embodiment, post-print processing further comprises a dual surfacing polishing step. In an embodiment, a dual surfacing polishing step further comprises securing the optical component via an edge of the optical component such that a first face and a second face of the optical component are accessible. In an embodiment, a dual surfacing polishing step further

‐ 55 ‐ comprises polishing an optical component on two faces simultaneously using, for example, a CNC machine. In an embodiment, the dual surface polishing comprises matching, random patterns on both faces such that the force applied by the polishing device administers equal forces at the same location at the same time on both faces of the optical component. This would facilitate maintenance of the geometry of the optical component throughout the polishing process as force from the polishing device on one face of the optical component without an equal force on the corresponding location on a second face has significant likelihood of causing physical deformation of the optical component. [0169] The post-print processing steps can occur in a variety of orders. In an embodiment, an excess resin removal step is performed first. In an embodiment, an excess resin removal step is a washing step, a spinning step, or a combination thereof. In an embodiment, post-print curing takes place immediately following the resin removal step. In an embodiment, post-print curing comprises UV curing, thermal curing, or a combination thereof. In an embodiment, a polishing step follows the post-print curing step. In an embodiment, a coating step follows the post-print curing step. In an embodiment, a spraying step follows the post-print curing step. In an embodiment, a polishing step, a spraying step, a coating step, or a combination thereof occurs after the excess resin removal step but prior to the post-print curing step. In an embodiment, multiple coating steps are performed. In an embodiment, a lens is coated with an index match material in order to remove any imperfections in optical lens precursor; then, a second, hard coating step is performed to imbue to the optical component with anti-abrasive and/or anti-reflective properties. In an embodiment, an optical lens is printed having microstructures on at least one face of the lens. A suitable microstructure may comprise a series of elevations and/or deformations having a depth into or out of at least one face of the lens of between 0.50 microns and 6.00 microns. A suitable microstructure may comprise a series of elevations and/or deformations at least approximately 36.0 microns apart. In an embodiment, a first coating step is performed prior to post-print curing and a hard coating step is performed after the post-print curing step. In an embodiment, a hard coating step is performed after a polishing step. In an embodiment, an optical component having a microstructure is coated such that a smooth surface is achieved after completion of the coating step. In an embodiment, a spin coating method is used. In an embodiment, a dip coating method is used. This would ensure that the lens is perfectly smooth prior to the hard coating step. This allows a hard coating material to be used that is non-index matching. This has the further benefit of

‐ 56 ‐ allowing an optical component comprising an optical lens precursor and a frame to be entirely coated in the anti-abrasive coating, which will increase the abrasion resistance of both the frames and the lenses in the final product. [0170] In an example, a coating step further comprises an additional UV curing step. Structural and chemical advantages are available if an additively manufactured product has not achieved 100% cure prior to additional post-processing steps. If the product has not been fully cured, then there are still reactive moieties present in and on the surface of the product. Functional groups may be covalently bound to these reactive moieties, which can provide additional functional and manufacturing benefits. In an embodiment, a coating step comprising an additional UV curing step allows for the hard coating to covalently bind to the exposed active groups of the green product. In an embodiment, an interface region is present in the final product between the additively manufactured lens and the hard coating. In an embodiment, hard coating in the presence of a UV cure creates stronger adhesion of the hard coating to the lens than coating in the absence of UV curing. In an embodiment, this forms a unique lens. In an embodiment, this invention provides an additively manufactured lens comprising a body layer, a coating layer, and an interface region said interface region comprising aspects of the body layer and the coating layer covalently bound to one another. In an aspect, the coating layer, is a hard coating. In an aspect, the coating layer is an anti-reflective coating. In an aspect, the coating layer is a blue light-absorbing coating. [0171] Combinations of components of steps will also be considered within the scope of the present invention, particularly where the ability to separate or combine is unclear or foreseeable. The disjunctive term “or”, as used herein and throughout the claims that follow, is generally intended to mean “and/or”, having both conjunctive and disjunctive meanings (and is not confined to an “exclusive or” meaning) unless otherwise indicated. As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Also as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. [0172] FIG.1 shows illustrative continuous vat polymerization printer 100. Printer 100 may include resin tank 102. The resin can be contained to the tank or can be flowing in and out of the tank. Printer 100 may include projector 104. Alternatively, projector 104 can be a liquid crystal display, laser, scanning laser projector. Printer 100 may include interface 106, which can be a liquid, gel, membrane, film or solid material transparent to the radiation. The interface can be

‐ 57 ‐ either stationary or mobile during the printing process. For example, the interface can be a fluorinated oil (e.g., perfluoropolyether copolymers, such as Solvay Fomblin Y or Chemours Krytox GPL). Projector 104 may emit radiation 108. Radiation 108 may penetrate interface 106. Radiation could be in the form of heat, magnetic radiation, or light (including UV, visible or infrared light, each of which can have a specific wavelength or broad band wavelength) . When radiation 108 contacts resin 110 in resin tank 102, resin 110 may begin to cure. Printer 100 may include build platform 112. Build platform 112 may be positioned near interface 106. Build platform 112 may be moved in the Z- or -Z-direction. Build platform may be moved in one or more of the X-, -X-, Y- and -Y-directions. Build platform 112 may be rotated. [0173] When build platform 112 positioned adjacent interface 106, resin 110 that is activated by radiation 108 may adhere to build platform 112. Build platform 112 may be drawn in the Z- direction with activate resin 110 attached. As build platform 112 is drawn in the Z-direction, additional resin 110 may be activated and may attach to resin 110 already attached to build platform 112. [0174] Resin 110 that is attached to build platform 112 may include monomers, oligomers. and polymers that are weakly bonded to each other. As the monomers, oligomers, and polymers are drawn by build platform 112, the monomers, oligomers, and polymers continue to receive energy from radiation 108. The energy causes the monomers, oligomers, and polymers to continue to bond to each other. [0175] Resin 110 attached to build platform 112 may form body B. Body B may have a straight proximal boundary (relative to interface 106, “P”). Body B may have a straight distal (relative to interface 106, “D”) boundary. Body B may have a curved proximal (relative to interface 106, “P”). Body B may have a nonlinear distal (relative to interface 106, “D”) boundary. Body B may have a non-uniform proximal boundary (relative to interface 106, “P”). P is where polymerization of resin begins to occur in the z direction. In the embodiment of Fig. 1, the top of the interface is where such polymerization of resin begins to occur and is thus P in that embodiment. [0176] Body B may include a Pre-Gelation Zone. In the Pre-Gelation Zone, resin body B is insufficiently cured to be considered a gel. Above gel point boundary GP, body B is a Gel Body. The Gel Body is a material that is cured sufficiently to hold its structure but continues to cure in the printing process.. In hardening zone HZ, the Gel Body continues to cure under the influence of radiation 108. Material at higher values of Z, may have been exposed longer to radiation 108,

‐ 58 ‐ and thus may be more cured than material at lower values of Z. The degree of curing may increase with increasing Z through Hardening Zone HZ. The radiation may be non-uniform both in X-Y and as a function of time. The degree of curing for a given Z may be different at different snapshots in time during a print. [0177] At the end of Hardening Zone HZ distal from the interface, the gel body may acquire rigidity that may not be present in regions of the gel body more proximal. At that end of Hardening Zone HZ, the body reaches a degree of cure that may be considered the Final Cure On Printer (“FCOP”). Above FCOP, it may be that little or no further curing occurs from projector 104. FCOP may be above, at or below surface 114 of resin 110. FCOP may be less than 100% fully cured. For example, FCOP may be 70-90% fully cured. Full cure may be performed off the printer. Sometimes the FCOP is an equal percentage, sometimes this is a range, and sometimes the FCOP is determined by the geometry of a body at every Z position. [0178] When build platform 112 is drawn in direction Z, reactive force F may result. Force F may result from adhesion between resin in Pre-Gelation Zone and interface 106. Force F may be proportional to (result from Stefan adhesion force resulting from the resin viscosity (α))(Body radius)4 x (1/(Body height (Z))3).in Pre-Gelation Zone and its thickness between interface 106 and the Gel Point GP. [0179] The size of Pre-Gelation Zone may be controlled to enhance the properties of body B. The Pre-Gelation Zone thickness PGZT is the distance from the boundary P to the boundary GP. [0180] FIG.2 shows printer 100 building body B1. In body B1 Pre-Gelation Zone thickness may vary across the width of body B1. For example, Pre-Gelation Zone thickness may be a function PGZT(x,y). The Pre-Gelation Zone may have a non-straight proximal boundary. The Pre-Gelation Zone may have a non-straight distal boundary. Hardening Zone HZ may have corresponding curvature. Hardening Zone HZ may have a straight proximal boundary. [0181] FIG.3 shows collimator 302, which may be included in printer 100. Collimator 302 may include a collimating lens, a condensing lens, or a series of lenses. Projector 104 may have an adjustable element that is configured to adjust the position of focal plane 304. Focal plane 304 is illustrated as being positioned at position Z1. Focal plane 304 may be aligned with an incident end of collimator 302. Collimator 302 may receive divergent pixels of radiation 108. Collimator 302 may split radiation 108 into divergent pixels. Collimator 302 may collimate the pixels. Each of the pixels may emerge from collimator 302 with an intensity distribution such as 306. Gaps

‐ 59 ‐ such as 308 may be present between the pixels. Gap 308 may be defined as an area that has an intensity that is lower intensity than the center of the pixel by at least 30%. Gaps 308 may cause optical aberrations extending in the Z-direction in body B. [0182] FIG.4 shows focal plane 304 positioned at position Z2. Focal plane 304 may be offset from the incident end of collimator 302. Collimator 302 may receive divergent pixels of radiation 108 in a less focused state when focal plane 304 is positioned at Z1. Each of the pixels may emerge from collimator 302 with an intensity distribution such as 406, which is more divergent than distribution 306. Distributions 406 may overlap and thus may remove gaps 308. The overlap may reduce or avoid the optical aberrations in body B. Focal plane 304 may move from Z1 to Z2 and back during the printing process. The focal plane 304 may move above Z1 and then move back down to either or both Z1 and Z2. [0183] FIG. 5 shows X-Y positioner 502, which may be included in printer 100. Pixels emerging from collimator 302 may emerge at angle α to collimator 302. Angle α may be 90°. X- Y positioner 502 may shift collimator 302 in plane X-Y. Collimator 302 is illustrated as being at position X1. [0184] X-Y positioner 502 may be instead attached to projector 104. This would result in a similar effect as Fig. 6. The X-Y positioner 502 may be attached to both projector 104 and collimator 302 to move them in unison. [0185] FIG.6 shows collimator 302 shifted from position X1 to position X2. When collimator 302 is displaced from projector 104, angle α may shift to an angle that is less than 90°. By shifting collimator 302, the emerging pixels may sweep across regions that may otherwise be affected by gaps such as 308. [0186] FIG. 7 shows a spatial distribution of radiation intensity corresponding to intensity distribution 306. [0187] FIG. 8 shows a spatial distribution of radiation intensity corresponding to intensity distribution 406. This spatial distribution may correspond also to time-averaged intensity distributions resulting from shifts in angle α. [0188] FIG. 9 shows illustrative printer 900. Printer 900 may have one or more features in common with printer 100. Printer 900 may include resin tank 902. Printer 900 may contain resin 910. Printer 900 may include build platform 912. Printer 900 may include projector 904. Projector 904 may extend in the X- or Y-directions farther than body B2.

‐ 60 ‐ [0189] Printer 900 may be configured to move build platform 912 along trajectory S(t). Trajectory S(t) may have a Z-component. Trajectory S(t) may have an X-component. Trajectory S(t) may have a Y-component. Trajectory S(t) may move in both the positive and/or negative direction and be at the same (X,Y) coordinate more than once. By moving build platform 912 along trajectory S, the emerging pixels may sweep across regions that may otherwise be affected by gaps such as 308. For a larger body B2, body B2 may have a trajectory S(t) that moves across multiple projectors 904 that are tiled together. Build platform 912 trajectory S(t) is relative to the radiation going through the interface and into the resin. This means the build platform 912 may not be moving in the X-Y plane relative to interface 906 and the resin tank 902. In this case the radiation would be the one moving in X-Y relative to interface 906 and the resin tank 902. [0190] Arrow A represents one or more axes of rotation of build platform 912. Printer 100 or 900 may rotate a build platform in one or more of the Z-X plane, the Z-Y plane, the X-Y plane, or an arbitrary oblique plane. The rotation may be dependent on time, position along S, or both. [0191] FIG.10 shows illustrative body B3 that may be printed by a printer such as 100 or 900. Body B3 may have one or more features in common with one or both of body B, body B1 and body B2. Body B3 may include support 1002. Body B3 may include lens 1004. Support 1002 may be monolithic with lens 1004. Body B3 may be cured on the printer to FCOP. Support 1002 may be engaged by a robot to subject lens 1004 to post-print treatments. Support 802 may adhere the lens 804 to the build platform 112 so that all three may be engaged in post-print treatments. [0192] FIG.11 shows body B3 from an angle orthogonal, about centerline CL, to the previous view of body B3. Lens 1004 may include surface S1. Lens 1004 may include surface S2. The printer may print body B3 based on a file that includes distance data for one or both of S1 and S2. The data may define distance function Ds1(Z,Y) for surface S1. The data may define distance function Ds2(Z,Y) for surface S2. Distance data for support 1002 may be included in the file. Support 1002 may be tapered to minimize material or to maximize stability. Ideally the support matches the dimensions of lens 1004 at the face where they join. Support 1002 may be an extension of the lens geometry with a face that has an X-Y profile to match and adhere to build platform 112. [0193] FIG.12 shows illustrative body B4 that may be printed by a printer such as 100 or 900. Body B4 may have one or more features in common with one or more of body B, body B1, body B2 and body B3. Body B4 may include support 1202. Body B4 may include lens 1204. Support 1202 may be monolithic with lens 1204. Body B4 may be cured on the printer to FCOP. Support

‐ 61 ‐ 1202 may be engaged by a robot to subject lens 1204 to post-print treatments. Support 1204 may be contiguous with perimeter 1206 of lens 1204. Body B4 may thus be seated in a frame for single- side chemical vapor deposition of lens coating material. Support 1204 may support body B4 in the frame in a manner that one side of lens 1204 faces a chemical vapor atmosphere. Support 1204 may prevent chemical vapor from traveling to the other side of lens 1204. Lens 1204 may have a range and shapes and sizes that utilize the same outer dimensions of 1202. [0194] FIG.13 shows body B4 from an angle orthogonal, about centerline CL, to the previous view of body B4. Lens 1204 may include surface S3. Lens 1204 may include surface S4. The printer may print body B4 based on a file that includes distance data for one or both of S1 and S2. The data may define distance function Ds3(Z,Y) for surface S3. The data may define distance function Ds4(Z,Y) for surface S4. Distance data for support 1202 may be included in the file. Support 1202 may taper or have thickness changes to make a more gradual or even seamless transition from the support to the lens 1204. [0195] Apparatus may omit features shown and/or described in connection with illustrative apparatus. Embodiments may include features that are neither shown nor described in connection with the illustrative apparatus. Features of illustrative apparatus may be combined. For example, an illustrative embodiment may include features shown in connection with another illustrative embodiment. [0196] For the sake of illustration, the steps of the illustrated processes will be described as being performed by a "system." A "system" may include one or more of the features of the apparatus and schemae that are shown or described herein and/or any other suitable device or approach. The "system" may include one or more means for performing one or more of the steps described herein. [0197] The steps of methods may be performed in an order other than the order shown and/or described herein. Embodiments may omit steps shown and/or described in connection with illustrative methods. Embodiments may include steps that are neither shown nor described in connection with illustrative methods. [0198] Illustrative method steps may be combined. For example, an illustrative process may include steps shown in connection with another illustrative process. [0199] FIG.14 shows illustrative steps of process 1400 for building a body using a controlled Pre-Gelation Zone thickness such as PGZT(x,y). The process may begin at step 1402. At step

‐ 62 ‐ 1402, the system may receive shape data. The shape data may be entered into the system by a user. The shape data may be included in an SDF file. [0200] At step 1404, the system may receive a selection of a parameter to control (e.g., a Pre- Gelation Zone thickness or a force F) and a control-value for the parameter (e.g., 300 micron for thickness or a desired number of Newtons for F). At step 1406, the system may receive resin kinetics parameters. The parameters may include activation energy. The parameters may include depth of penetration. [0201] At step 1408, the system may output a process parameter. The process parameter may include a pull rate at which the build platform is to be moved. The process parameter may include a light intensity. The light intensity may be expressed as a percentage of a maximum light intensity. The light intensity may be expressed as a power/unit-area. The light intensity may correspond to a light intensity incident on the interface. [0202] At step 1410, the system may receive feedback. The feedback may include a Pre- Gelation Zone thickness. The feedback may include a force F. The feedback may include a light intensity. The feedback may include a pull rate. The feedback may include a resin temperature. The feedback may include a resin cure-degree. The cure-degree may be based on optical transmissivity. The cure degree may be based on scanning calorimetry. The feedback may be generated by telemetry. The feedback may be acquired by observation by a user. [0203] FIG. 15 shows illustrative steps of process 1500 for building a body with aberration mitigation. At step 1502, the system may receive an SDF file that defines a first lens surface. At step 1504, the system may receive data that defines a second lens surface. The second lens surface may be defined in a separated SDF file. The second lens surface may be defined in the same SDF file as that in which the first lens surface is defined. [0204] At step 1506, the system may identify N X-Y slices, through the body to be built, based on the first and second lens surface data. [0205] At step 1508, the system may assign a radiation intensity instruction to each pixel in each slice. Radiation intensity instructions may be assigned on a slice-by-slice basis. [0206] At step 1510, the system may assign an aberration mitigation instruction to each pixel in each slide or to each slice. The aberration mitigation instruction may correspond to a change in focal length of the projector. The aberration mitigation instruction may correspond to a change in

‐ 63 ‐ the angle of incidence of the pixels on the interface. The aberration mitigation instruction may include a trajectory (such as S), or a trajectory speed (such as dS/dt). [0207] At step 1512, the system may cause the projector to move the build platform and project radiation, for each slice of the body (starting adjacent the build platform) based on the radiation intensity instruction and the aberration mitigation instruction. [0208] At step 1514, the system may receive feedback. The feedback may include a pre- gelation zone thickness. The feedback may include a force F. The feedback may include a light intensity. The feedback may include a pull rate. The feedback may include a resin temperature. The feedback may include a resin cure-degree. The cure-degree may be based on optical transmissivity. The cure degree may be based on scanning calorimetry. The feedback may be based on optical scattering that is responsive to variations of cure degree in the body. The feedback may be generated by telemetry. The feedback may be acquired by observation by a user. [0209] FIG.16 illustrates an interface layer 1610 in which stress bands may occur because of the collimating lens 1600. [0210] At 1613, a window is shown to allow for the projection of radiation therethrough. An interface bubble is shown at 1614. Such a bubble 1614, which may be formed as a result of application of a force to the cured or semi-cured part, may itself act like a lens and cause uneven curing of the part in the resin layer 1620. [0211] FIG. 17 illustrates a collimating lens 1700, an interface layer 1710, a window 1713, and the resin layer 1720. FIG.17 also shows scattering particles 1712 in the resin. [0212] FIG. 17 illustrates the use of collimating lens 1700 in combination with scattering particles 1712 at the interface. Such a combination preferably results in an even cure with no, or substantially no, stress bands in the cured lens. The embodiment shown in FIG.17 is yet another example of a method of mitigating aberrations in the cured lens. [0213] FIG. 18 shows yet another approach to mitigating aberrations. Specifically, FIG. 18 shows pixel-blurring by overlapping projection areas of multiple projectors 1800. [0214] At 1801, a single projector is shown. At 1802 an area of radiation is indicated. At 1804, an exploded diagram of the area indicated at 1802 is shown. It should be noted that, at the various areas of radiation of exploded diagram 1804, stress regions may occur because the pixels are cured individually in a non-blurred fashion. Such a non-blurred curing may cause areas of

‐ 64 ‐ relatively low intensity radiation between areas of high intensity radiation. Such areas of low intensity may cause uneven curing, and possibly stress bands. [0215] At 1800, pixel blurring using overlapping projection area of multiple projects 1800 is shown. Specifically, 1803 shows a cured region. At 1806, an exploded diagram of the region indicated at 1803 is shown. It should be noted that at the various regions 1806 of exploded diagram 1803 stress regions have been eliminated because the pixels are cured in a blurred fashion due to the multiple projectors 1800. Such blurred pixels may obtain curing absent stress bands. [0216] FIG.19 shows a physical mask for disposing over a projector, as set forth herein. The physical mask may be used for shaping a perimeter of a body-cross section. [0217] At 1900, a curved projector mask is shown. At 1910, a mask base is shown. At 1920, two opposing faces of a linear actuator are shown. At 1930, a flexible bladder is shown. [0218] FIG.20 shows a method of precise building of a body cross-section (see, e.g., supra, at FIG.9, printer 900.) [0219] At 2010, an interface is shown. At 2020, a resin layer is shown. An adhesion stage 2002 is shown. At 2030, an optical component, having a curve, is shown. At 2040, an adhesion stage is shown. Thus, FIG.20 shows a curved direction of pull wherein the normal of the curve of optical component 2030, such as a lens, remains perpendicular, or substantially perpendicular, to interface 2010. At 2000, a radiation source including a projection area is shown. [0220] FIG.21 shows selectively inhibiting curing using multiple radiation sources. FIG.21 illustrates multiple curing radiation sources 2100. At 2141, an interface 2110 is shown. At 2120, a resin layer is shown. At 2140, an adhesion stage is shown. At 2102, multiple radiation sources are shown. Radiation sources 2102 may be used to selectively inhibit curing. [0221] FIG. 22 shows a cross-sectional view of an embodiment of an optical lens 2210. Optical lens 2210 preferably includes an optical lens body layer 2211, an optical lens coating layer 2212 and an interface region 2213. Interface region 2213 is disposed between optical lens body layer 2211 and optical lens coating layer 2212. [0222] FIG. 23 shows a top plan view of an optical lens support structure. The optical lens support structure shows a multi-build platform design wherein each build platform comprises an identifier for the associated optical lens component. Specifically, FIG.23 shows bar codes 2341 disposed on the optical lens support structure.

‐ 65 ‐ [0223] Such a support structure may include projections 2340, upon which the bar codes may be etched, embossed or otherwise indicated. Projections 2340 may extend from structure spine 2345. Such bar codes 2341 may be used with robotic wet coating. Such wet coating may implement dipping. [0224] FIG. 24 shows a side view of the optical lens support structure shown in FIG. 23. Specifically, FIG.24 shows a side view of projections 2440 and spine 2445. In addition, FIG.24 shows a square structure at 2430 an adhesion stage embodiment at 2432. In addition, FIG. 24 shows a plurality of optical lenses 2400. [0225] FIG. 25 shows a perspective view of an optical component 2500. The optical component includes a support structure 2530. In addition to optical component 2500 being shown in FIG.25, a vapor coating apparatus is also shown, at 2550. [0226] Optical component 2500 further includes an optical lens pre-cursor 2520, a first face 2521 and a rim 2523. At 2531, a square embodiment of the support structure is shown. [0227] At FIG.26, a plan view of the optical component from the FIG.25 is shown. [0228] Optical component 2600 includes a support structure 2630. [0229] Optical component 2600 further includes an optical lens pre-cursor 2620, a first face 2621 and a rim 2623. [0230] At 2631, a square embodiment of the support structure is shown. Square embodiment is shown as having an exemplary length and width of 85 millimeters (“mm”), although other suitable lengths and/or widths, such as 65 mm, are also within the disclosure of this application. [0231] FIG.27 shows a plan view of the embodiment from FIG.26. However, FIG.27 also shows an additional embodiment of an optical component 2700. It should be noted that, although support structure 2630 shown in FIG.6 is the same size as support structure 2730 shown in FIG. 27 – i.e., 85 mm, optical component 2600 shown in FIG. 26 has a different size than optical precursor 2700 shown in FIG.27. [0232] FIG.28 shows a perspective view of an alternate embodiment of an optical component 2800. Optical component 2800 includes a support structure 2830. [0233] Support structure 2830 includes an adhesion stage 2840 for attachment to a spin coating apparatus 2802. Optical component 2800 further includes an optical lens pre-cursor 2820, a first face 2821, a second face 2822 and a rim 2823. An adhesion stage embodiment 2832 of support structure 2830 is also shown.

‐ 66 ‐ [0234] FIG. 29 shows a perspective view of an alternate embodiment of optical component 2900. Optical component 2900 includes an adhesion stage embodiment 2932 of support structure 2930, as well as vapor coating structure 2902. Optical component 2900 further includes an optical lens pre-cursor 2920, a first face 2921 and a rim 2923 such that a preferably airtight seal forms (indicated schematically) at the rim of optical component 2900. [0235] FIG. 30 is a block diagram that illustrates a computing server 3001 (alternatively referred to herein as a "server or computer") that may be used in accordance with the principles of the invention. The server 3001 may have a processor 3003 for controlling overall operation of the server and its associated components, including RAM 3005, ROM 3007, input/output (“I/O”) module 3009, and memory 3015. [0236] I/O module 3009 may include a microphone, keypad, touchscreen and/or stylus through which a user of server 3001 may provide input, and may also include one or more of a speaker for providing audio output and a video display device for providing textual, audiovisual and/or graphical output. Software may be stored within memory 3015 and/or other storage (not shown) to provide instructions to processor 3003 for enabling server 3001 to perform various functions. For example, memory 3015 may store software used by server 3001, such as an operating system 3017, application programs 3019, and an associated database 3011. Alternatively, some or all of computer executable instructions of server 3001 may be embodied in hardware or firmware (not shown). [0237] Server 3001 may operate in a networked environment supporting connections to one or more remote computers, such as terminals 3041 and 3051. Terminals 3041 and 3051 may be personal computers or servers that include many or all of the elements described above relative to server 3001. The network connections depicted in FIG. 30 include a local area network (LAN) 3025 and a wide area network (WAN) 3029, but may also include other networks. [0238] When used in a LAN networking environment, server 3001 is connected to LAN 3025 through a network interface or adapter 3013. [0239] When used in a WAN networking environment, server 3001 may include a modem 3027 or other means for establishing communications over WAN 3029, such as Internet 3031. [0240] It will be appreciated that the network connections shown are illustrative and other means of establishing a communications link between the computers may be used. The existence of any of various well-known protocols such as TCP/IP, Ethernet, FTP, HTTP and the like is

‐ 67 ‐ presumed, and the system may be operated in a client-server configuration to permit a user to retrieve web pages from a web-based server. Any of various conventional web browsers may be used to display and manipulate data on web pages. [0241] Additionally, application program 3019, which may be used by server 3001, may include computer executable instructions for invoking user functionality related to communication, such as email, short message service (SMS), and voice input and speech recognition applications. [0242] Computing server 3001 and/or terminals 3041 or 3051 may also be mobile terminals including various other components, such as a battery, speaker, and antennas (not shown). [0243] Terminal 3051 and/or terminal 3041 may be portable devices such as a laptop, tablet, smartphone or any other suitable device for receiving, storing, transmitting and/or displaying relevant information. [0244] Any information described above in connection with database 3011, and any other suitable information, may be stored in memory 3015. One or more of applications 3019 may include one or more algorithms that may be used to perform the functions of a continuous vat polymerization printer and perform any other suitable tasks. [0245] The apparatus and methods may be operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well- known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to, personal computers, server computers, hand-held or laptop devices, tablets, mobile phones and/or other personal digital assistants (“PDAs”), multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like. [0246] The apparatus and methods may be described in the general context of computer- executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. The invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing

‐ 68 ‐ environment, program modules may be located in both local and remote computer storage media including memory storage devices. [0247] FIG.31 shows illustrative apparatus 3100 that may be configured in accordance with the principles of the invention. [0248] Apparatus 3100 may be a computing machine. Apparatus 3100 may include one or more features of the apparatus that is shown in FIG.30. [0249] Apparatus 3100 may include chip module 3102, which may include one or more integrated circuits, and which may include logic configured to perform any other suitable logical operations. [0250] Apparatus 3100 may include one or more of the following components: I/O circuitry 3104, which may include a transmitter device and a receiver device and may interface with fiber optic cable, coaxial cable, telephone lines, wireless devices, PHY layer hardware, a keypad/display control device or any other suitable encoded media or devices; peripheral devices 3106, which may include counter timers, real-time timers, power-on reset generators or any other suitable peripheral devices; logical processing device 3108, which may solve equations and perform other methods described herein; and machine-readable memory 3110. [0251] Machine-readable memory 3110 may be configured to store in machine-readable data structures associated with a continuous vat polymerization printer, a lens pre-cursor and any other suitable information or data structures. [0252] Components 3102, 3104, 3106, 3108 and 3110 may be coupled together by a system bus or other interconnections 3112 and may be present on one or more circuit boards such as 3120. In some embodiments, the components may be integrated into a single chip. [0253] The chip may be silicon-based. [0254] The apparatus and methods may involve modeling or testing, or receiving modeled or test values of, activation energy (Ec) and depth of penetration (Dp). [0255] Such a model may start with traditional kinetic curing of the polymerization process. Equation (1) states that the time rate of change of the monomer concentration [M] may defined to be the rate of polymerization ^^_^ with ^^_^ being the rate of free radical initiation. ^^ ^ ^{ௗ^ெ^} ^ ^^_^ ^ ^^_^ ൌ െ (1)

[0256] The rate of polymerization may be defined as ^^_^ ൌ ^^_^^ ^^^^ ^^^∗^ (2) [0257] where ^^_^ is the kinetic rate constant for propagation and ^ ^^^∗^ is the radical chain concentration. Employing the steady state approximation, namely the initiation of radicals equals termination, may provide that [0258] ^^{^} _^ ^{ൌ ^^} _^ ^{^ ^^^} _^ ^{ோ^} ଶ_^^ ⁽³⁾ [0259] where ^^_௧ is the kinetic rate constant for termination. The initiation rate may be related to the photonic flux I(z) as a function of depth z by ^^_^ ൌ 2∅ ∈ ^ ^^ ^^^ ^^^ ^^^ (4) [0260] with ∅ being the quantum yield, [PI] the photo initiator concentration {M} and ∈ is the molar extinction coefficient { L-1M-1}. [0261] The intensity at depth z may be found from Beer’s Law ^^^ ^^^ ൌ ^^_^ ^^^{ି∈ ^^ூ^ ௭} (5) [0262] and therefore equation (4) may be cast as ^_{^^ ൌ 2∅ ∈} ^{^} _{^^ ^^} ^{^} _{^^^ ^^} ^{ି∈ ^^ூ^ ௭} ₍₆₎ [0263] Substituting equation (6) into equation (3) yields ^_{^ ൌ െ} ^{ௗ^ெ^} =_^^ ^{^ ^^∅∈^^ூ^ ூబ ^ష∈ ^ು^^ ^} ^_{^ ^^} (7) [0264] Equation (7) may be

మ^{^ ష∈ ^ು^^ ^} ^_{^ ൌ െ} ^{ௗ^ெ^ ^ ^^ ∅ ∈ ^ூ^ ூబ ^} ^₌ (8)

[0265] Assuming the terms under the radical are independent of time, both sides of equation (8) may be used to obtain the following expression for the degree of polymerization ^_{∅ ∈ ^^ூ^ ூ} ^{∈ ು^ ^ ିభ} ^{మ ష ^ ^ మ} ^^ ^^ ^^{^ெబ^} ^ _{^ బ ^} _^ெ^ ൌ ^ _^^ ൨ ^^ (9) [0266] where the

^_ெబ ^{^} ^_ெ^ ൌ ^̅^ (10)

[0267] noting ^ ^^_^^ is the initial concentration of monomer ^ ^^^ at time ^^ ൌ 0. It may be desirable to define the extent of polymerization p in terms of the degree of polymerization as follows: ^̅^ ൌ ^{^} ^_ି^ (11)

[0268] Utilizing equations (10) and (11) equation (8) may be rewritten as follows: ^^{^^^^ି^^ ଶ} ^ _{^^ ൌ} ^{^ ^ ି∈ ^^ூ^ ௭} ௧_{^^మ ∅ ∈ ூబ ^^ ^^ ^^ (12)} _{[0269] It may be}

of testing and modeling. ^^{^} _{^ ൌ} ^{^^మ ∅} ^_{^ (13)}

[0270] Therefore equation (12) may now be written as: ^_^^^^ି^^^ ^మ ^{ି∈ ^^ூ^} మ_ൌ ^{^} _{^^ ^^} ^{^} _^^ ^௭ ₍₁₄₎ [0271] At the gel point the

correspond to a Pre-Gelation Zone, as referred to herein. Also denote the time of cure as tc which is also the duration of the exposure time that the light source remains on exposing the resin to UV

‐ 71 ‐ light. Utilizing equation (14) along with parameters defined at the gel point above, equation (13) may be rewritten as follows: ^_^^^^ି^^^^ ^మ ൌ ^{^} _^ ^{^ ି∈ ^^ூ^ ௭^} ఉ_{^ ∈ ூబ ௧^మ ^ ^^ ^^ (15)}

[0272] Taking the an cure depth as follows: ௧^{^^ఉ^∈ூబ^^ூ^} ^^_^ ൌ ^ଶ ^^ ^^ (16)

[0273] By inspection of equation (16) one may see the competing nature of the product of molar extinction coefficient and concentration of photo inhibitor. [0274] In order to maximize cure depth with respect to [PI] one may take the derivative of equation (16) with respect to [PI]. However, noting that the product or [PI] and ∈appear together one may define a new parameter. ^^^ ൌ∈ ^ ^^ ^^^ (17) being the extinction coefficient with units of {L}-1. The cure depth evolution in equation (16) may be given by ଶ^{௧^^ఉ^ூబఈ^}

[0275] Now one may find the value of ^^^ that maximizes cure depth by

‐ 72 ‐ √^{^^} _^ ^{^} _^ ^{^} _^ ^^{ିଶ^^^} _{^ బ} ௗ^{ଶ ^ ఉூబఈ} _{ಲಳೄ ^^^^ ^} ^{^} ^{௧ ^^ ^} _{భష^^ ^} ^^ ^^

[0276] Setting the derivative in the above equation one may obtain an expression for the value of ^^^ that maximizes cure depth as: మ ^^^ ^{^ ୪୬ ^^ି^} ^_^௫ ൌ ^{^^} ௧_{^మ ఉ^ ூబ} (19) [0277] There are at

needs for input as well as providing output data for. Exposure time ^^_^ and light intensity ^^_^ at the image plane may both be inputs to a testing approach. For each test specimen subjected to various exposure time a gelatinous square with unique thickness ^^_^ may be obtained. [0278] In addition to the foregoing, it is likely the photo inhibitor concentration [PI] and the molar extinction coefficient ∈ will be known. Therefore, the following parameters may be obtained thru regression analysis utilizing equation (15): Regression Analysis P_arameters ^{^^^ ^^^} Table 1 [0279] If the photo inhibitor concentration and molar extinction values are not known then regression analysis for the following may be desired along with equation (15): Regression Analysis P_arameters ^{^^^ ^^^ ∈ [PI]} Table 2 [0280] A way to capture more fidelity in testing would be to vary the intensity of the EcDp testing namely ^^_^. The additional variable intensity may give more fidelity to the determination of regression analysis parameters that help to characterize the cure process. The additional fidelity

‐ 73 ‐ obtained in parameter values may be exploited in the modeling of the printing process itself. It may be desirable to utilize ^^^{^}^ in equation (17) to determine the regression analysis parameters as Regression Analysis P_arameters ^{^^^ ^^^ ^^^} Table 3 [0281] Using equation (15) and one or more of the inputs below a regression analysis may be performed to determine the unique parameters displayed in Table 1 and 2. Or using equation (17) Table 3 may be employed. Table 4 and 5 show two testing schemas where m is the test number and n is the subset variation within the test. Each test m may have a constant intensity with increasing exposure time giving n unique cure depths that increase over time. [0282] A regression algorithm may be employed to determine the “best” fit for the regression analysis parameters. Once completed a unique single value for each parameter - beta, degree of cure, molar extinction coefficient and photo inhibitor concentration – may be obtained. Test Inputs Measured Regression Analysis on Parameters Number Molar Photo Intensity Duration ^Cure D_epth Beta Degree of Cure Extinction Inhibitor Coefficient Conc. ^^{^^^1^ ^^^^1,1^ ^^^^1,1^ ^^^(1,1) ^^^^1,1^ ∈ (1,1) [PI] (1,1)} 1 _{^^^^1^ ^^^^1,2^ ^^^^1,2^ ^^^(1,2) ^^^^1,2^ ∈ (1,2) [PI] (1,2)} …^{… … … … … …} ^_{^^^1^ ^^^^1, ^^^ ^^^^1, ^^^ ^^^(1,n) ^^^^1, ^^^ ∈ (1,n) [PI] (1,n)} ^^{^^^2^ ^^^^2,1^ ^^^^2,1^ ^^^(2,1) ^^^^2,1^ ∈ (2,1) [PI] (2,1)} 2 _{^^^^2^ ^^^^2,2^ ^^^^2,2^ ^^^(2,2) ^^^^2,2^ ∈ (2,2) [PI] (2,2)} …^{… … … … … …} ^_{^^^2^ ^^^^2, ^^^ ^^^^2, ^^^ ^^^(2,n) ^^^^2, ^^^ ∈ (2,n) [PI] (2,n)} ^^{^^^ ^^^ ^^^^ ^^, 1^ ^^^^ ^^, 1^ ^^^(m,1) ^^^^ ^^, 1^ ∈ (m,1) [PI] (m,n)} m _{^^^^ ^^^ ^^^^ ^^, 2^ ^^^^ ^^, 2^ ^^^(m,2) ^^^^ ^^, 2^ ∈ (m,2) [PI] (m,2)} …^{… … … … … …} ^_{^^^ ^^^ ^^^^ ^^, ^^^ ^^^^ ^^, ^^^ ^^^(m,n) ^^^^ ^^, ^^^ ∈ (m,n) [PI] (m,n)} Table 4 Test Inputs Measured Regression Analysis on Parameters Number

‐ 74 ‐ ntensity Duration ^C Degree of I ^ure D_epth Beta _Cure ^alpha ^{^^^^1^ ^^^^1,1^ ^^^^1,1^ ^^^(1,1) ^^^^1,1^ ^^^(1,1)} 1 _{^^^^1^ ^^^^1,2^ ^^^^1,2^ ^^^(1,2) ^^^^1,2^ ^^^(1,2)} …^{… … … … …} ^_{^^^1^ ^^^^1, ^^^ ^^^^1, ^^^ ^^^(1,n) ^^^^1, ^^^ ^^^(1,n)} ^^{^^^2^ ^^^^2,1^ ^^^^2,1^ ^^^(2,1) ^^^^2,1^ ^^^(2,1)} ^_{^ ^2^ ^^ ^2,2^ ^ ^ ^^^(2,2)} 2 _{^ ^ ^^^2,2^ ^^(2,2) ^^^^2,2^} …^{… … … … …} ^_{^^^2^ ^^^^2, ^^^ ^^^^2, ^^^ ^^^(2,n) ^^^^2, ^^^ ^^^(1,n)} ^^{^^^ ^^^ ^^^^ ^^, 1^ ^^^^ ^^, 1^ ^^^(m,1) ^^^^ ^^, 1^ ^^^(m,1)} ^_{^ ^ ^^^ ^^ ^ ^ ^^^(m,2)} m _{^ ^ ^^, 2^ ^^^^ ^^, 2^ ^^(m,2) ^^^^ ^^, 2^} …^{… … … … …} ^_{^^^ ^^^ ^^^^ ^^, ^^^ ^^^^ ^^, ^^^ ^^^(m,n) ^^^^ ^^, ^^^ ^^^(m,n)} Table 5 [0283] One possible outcome of the above analysis and testing schema is the ability test various resin – photo initiator combinations, at different intensities for multiple durations, to obtain valuable parametric values unique to that system’s recipe. These unique parametric values may characterize the recipes curing profile uniquely. [0284] Equation (17) as described above is an equation for how gel thickness may evolve for various intensity levels over time. Therefore, by utilizing material testing described above one may predict gel thickness evolution for any combination of resin material and projector variables such as photo initiator concentration, intensity and exposure time. [0285] A regression analysis algorithm may be executed to take in testing inputs and determine parameters for any of the data sets such as those in Table 1 through 3. As an example, the testing schema needed for parameter family in Table 3 is given in Table 5. For one recipe in Table 5 the regression analysis finds the “best” fit combination the beta, degree of cure and alpha values that characterize the entire cure profile as seen in Figure 32 and 33. [0286] The blue line in Figure 32 is a characteristic cure equation that may predict the cure depth as a function of energy density as described in equation (17). The parameters obtained from the regression analysis depicted in Figure 33 may be used to generate a curing profile that is compared to the actual data shown by the orange curve in Figure 32. The parameters ^^^, ^^{^}^ , ^^_^ and critical energy density may characterize resin, photo initiator, UV light intensity as a system.

‐ 75 ‐ [0287] As comparison Figures 34 and 35 below show similar testing and cure depth characterization curve results as Figures 32 and 33. The difference between the two sets is Figures 34 and 35 are the same resin as Figures 32 and 33 but increased photo inhibitor concentration going from 0.8 % to 1.2 % by weight. While the two systems curves appear to be similar in nature, they are not, as can be seen by inspecting the two sets of unique parameter sets in Figures 34 and 35. [0288] Given a resin, photo initiator, UV light intensity system, it may be predicted how the material will evolve over time. Furthermore, by knowing how any given material will evolve in a system, part features and properties of interest may be controlled and exploited. In particular, geometric part quality, dimensional accuracy and green strength may be treated as functions of the cure depth evolutions displayed in section 6. This evolution can be exploited and tuned by one or more printer controls such as print speed, part orientation, as well as variable light intensity over time, among others. ILLUSTRATIVE EMBODIMENTS PRE-GELATION ZONE SOFTWARE EMBODIMENTS 1. A non-transitory computer-readable medium storing instructions for producing an optical lens body, that when the instructions are executed by a continuous vat polymerization printer cause the continuous vat polymerization to perform a method comprising: projecting radiation into a resin; drawing a gel body away from a projector that provides the radiation; and controlling a thickness of a pre-gelation zone extending from the resin to the gel body. 2. The medium of embodiment 1 wherein, in the method, the controlling comprises: receiving a thickness control-value; and setting a rate of the drawing to obtain a thickness that corresponds to the thickness control-value.

‐ 76 ‐ 3. The medium of embodiment 2 wherein, in the method, the controlling further comprises setting an intensity of the radiation that corresponds to the thickness control- value. 4. The medium of embodiment 1 wherein, in the method, the controlling comprises: receiving a thickness control-value; and setting a rate of the drawing and an intensity of the radiation to obtain a thickness that corresponds to the thickness control-value. 5. The medium of embodiment 2 wherein: the method further comprises receiving a resin activation energy corresponding to the resin; and the setting is based on the activation energy. 6. The medium of embodiment 2 wherein: the method further comprises receiving a resin penetration depth corresponding to the resin; and the setting is based on the penetration depth. 7. The medium of embodiment 2 wherein the method further comprises: receiving a full-cure-on-printer value; and the setting is based on the full-cure-on-printer value. 8. The medium of embodiment 3 wherein the method further comprises: receiving an indication corresponding to an observed pre-gelation zone thickness; and adjusting the rate based on the observed pre-gelation zone thickness. 9. The medium of embodiment 8 wherein: the printer includes an optical sensor that is configured to generate a signal that corresponds to the observed pre-gelation zone thickness; adjusting includes receiving the signal; and adjusting the rate based on the signal.

‐ 77 ‐ 10. The medium of embodiment 8 wherein the method further comprises adjusting the intensity based on the observed pre-gelation zone thickness. 11. The medium of embodiment 3 wherein: the method further comprises receiving an indication corresponding to an observed pre-gelation zone thickness; and adjusting the intensity based on the observed pre-gelation zone thickness. 12. The medium of embodiment 3 wherein the method further comprises: receiving an indication corresponding to an observed force corresponding to the drawing; and adjusting the rate based on the observed force. 13. The medium of embodiment 12 wherein the method further comprises adjusting the intensity based on the observed force. 14. The medium of embodiment 3 wherein: the method further comprises receiving an indication corresponding to an observed force corresponding to the drawing; and adjusting the intensity based on the observed force. 15. The method of embodiment 1 wherein, in the method, the pre-gelation zone thickness is defined as being parallel to a direction of the drawing. 16. The method of embodiment 15 wherein, in the method, the pre-gelation zone thickness is defined as being adjacent a portion of the gel body that is closest to the projector. 17. The method of embodiment 15 wherein, in the method, the pre-gelation zone thickness is defined as being offset, in a direction transverse to the direction of the drawing, from a portion of the gel body that is closest to the projector. 18. The method of embodiment 15 wherein, in the method, the pre-gelation zone thickness is defined as being an average of pre-gelation zone thickness that vary transversely across a curved end of the gel body that is closest to the projector.

‐ 78 ‐ 19. The method of embodiment 1 wherein the gel body elongates in a direction that is not perpendicular to a direction of the drawing. 20. The method of embodiment 1 wherein the gel body elongates in a direction that is parallel to a direction of the drawing. 21. The method of embodiment 15 wherein the method further comprises: receiving offset values, each corresponding to an offset, in a direction transverse to the direction of the drawing, from a portion of the gel body that is closest to the projector; and receiving, for each offset, a thickness control-value; and the controlling includes selecting one of the thickness control-values to be the thickness. 22. The method of embodiment 15 wherein the method further comprises: receiving offset values, each corresponding to an offset, in a direction transverse to the direction of the drawing, from a portion of the gel body that is closest to the projector; and receiving, for each offset, a thickness control-value; and the controlling includes selecting an average of the thickness control-values to be the thickness. 23. The medium of embodiment 1 wherein, in the method, the body is a green body. 24. The medium of embodiment 1 wherein: the method further comprises: receiving: an overall body length corresponding to a planned length of the printed body; and a margin percent corresponding to an edge of the planned length; detecting when the pre-gelation zone reaches the edge; and the controlling comprises reducing the thickness when the pre-gelation zone reaches the edge.

‐ 79 ‐ 25. The medium of embodiment 24 wherein, in the method, the planned length corresponds to a length of a lens precursor. 26. The medium of embodiment 24 wherein, in the method, the planned length corresponds to a combined length of a lens precursor and an excess margin that is configured for post printing excision. 27. The medium of embodiment 1 wherein: the method further comprises: receiving: an overall body length corresponding to a planned length of the printed body; and a margin percent corresponding to an edge of the planned length; and the controlling comprises maintaining the thickness at: a first value corresponding to the edge; and a second value that is greater than the first value during curing of the planned length. 28. The medium of embodiment 27 wherein, in the method, the planned length corresponds to a length of a lens precursor. 29. The medium of embodiment 27 wherein, in the method, the planned length corresponds to a combined length of a lens precursor and an excess margin that is configured for post printing excision. 30. The medium of embodiment 1 wherein: in the method, the radiation is a first radiation; and the method further comprises projecting a second radiation that is configured to activate a photo-activated curing blocker at a portion of the gel body to inhibit curing. 31. A non-transitory computer-readable medium storing instructions for producing an optical lens body, that when the instructions are executed by a continuous vat polymerization printer cause the continuous vat polymerization to perform a method comprising:

‐ 80 ‐ projecting radiation into a resin; drawing a gel body away from a projector that provides the radiation, the drawing generating a force that acts in a direction opposite a direction of the drawing; and controlling the force to obtain a pre-gelation zone thickness, the pre-gelation zone extending from the resin to the gel body. 32. The medium of embodiment 31 wherein, in the method, the controlling comprises: receiving a force control-value; and setting a rate of the drawing to obtain a force that corresponds to the force control-value. 33. The medium of embodiment 32 wherein, in the method, the controlling further comprises setting an intensity of the radiation that corresponds to the force control-value. 34. The medium of embodiment 32 wherein, in the method, the controlling comprises: receiving a force control-value; and setting a rate of the drawing and an intensity of the radiation to obtain a force that corresponds to the force control-value. 35. The medium of embodiment 32 wherein: the method further comprises receiving a resin activation energy corresponding to the resin; and the setting is based on the activation energy. 36. The medium of embodiment 32 wherein: the method further comprises receiving a resin penetration depth corresponding to the resin; and the setting is based on the penetration depth. 37. The medium of embodiment 32 wherein the method further comprises: receiving a full-cure-on-printer value; and the setting is based on the full-cure-on-printer value.

‐ 81 ‐ 38. The medium of embodiment 32 wherein the method further comprises: receiving an indication corresponding to an observed pre-gelation zone thickness; and adjusting the rate based on the observed pre-gelation zone thickness. 39. The medium of embodiment 33 wherein the method further comprises adjusting the intensity based on an observed pre-gelation zone thickness. 40. The medium of embodiment 33 wherein: the method further comprises receiving an indication corresponding to an observed pre-gelation zone thickness; and adjusting the intensity based on the observed pre-gelation zone thickness. 41. The medium of embodiment 32 wherein the method further comprises: receiving an indication corresponding to an observed force corresponding to the drawing; and adjusting the rate based on the observed force. 42. The medium of embodiment 33 wherein the method further comprises adjusting the intensity based on an observed force. 43. The medium of embodiment 33 wherein: the method further comprises receiving an indication corresponding to an observed force corresponding to the drawing; and adjusting the intensity based on the observed force. 44. The medium of embodiment 33 wherein: the printer includes an interface and a collimating lens that is configured to collimate radiation entering the interface; and, in the method, the drawing includes moving a build platform, to which the gel body is attached, in a first direction that is perpendicular to the interface and a second direction that is parallel to the interface.

‐ 82 ‐ ABERRATION MITIGATION EMBODIMENTS 1. A non-transitory computer-readable medium storing instructions for producing an optical lens body, that when the instructions are executed by a continuous vat polymerization printer cause the continuous vat polymerization to perform a method comprising: projecting pixelated radiation into a resin; drawing a gel body away from a projector that provides the radiation; and controlling a beam characteristic of each pixel in the pixelated radiation. 2. The medium of embodiment 1 wherein, in the method: the projecting includes reflecting a source light beam off a digital micromirror device having a plurality of micromirrors, each of which is individually controllable; and each pixel corresponds to one of the micromirrors. 3. The medium of embodiment 1 wherein, in the method, the beam characteristic includes a radiation intensity. 4. The medium of embodiment 3 wherein: the printer includes an interface that defines a plane; and, in the method, the controlling includes varying intensity of the radiation as a function of time and location along the plane. 5. The medium of embodiment 1 wherein, in the method, the beam characteristic is an angular distribution of intensity. 6. The medium of embodiment 5 wherein: the printer includes an interface that defines a plane; and, in the method, the controlling includes changing the angular distribution. 7. The medium of embodiment 6 wherein: the printer includes a projector that is configured to project light having an adjustable focal length; and, in the method, the changing includes adjusting the focal length.

‐ 83 ‐ 8. The medium of embodiment 7 wherein, in the method, the adjusting includes moving a focal plane of the light away from an incidence surface of a collimating lens. 9. The medium of embodiment 7 wherein, in the method, the changing includes sharpening the distribution 10. The medium of embodiment 7 wherein, in the method, the changing includes flattening the distribution. 11. The medium of embodiment 7 wherein, in the method: a first pixel has a first angular distribution of intensity; a second pixel disposed next to the first pixel has a second angular distribution of intensity; and the changing includes causing the first and second angular distributions of intensity to overlap so that radiation entering the resin has a maximum spatial intensity variation of no more than a predetermined percent of the average intensity of all the pixels. 12. The medium of embodiment 11 wherein, in the method, the selected percent is 20%. 13. The medium of embodiment 11 wherein, in the method, the selected percent is 15%. 14. The medium of embodiment 11 wherein, in the method, the selected percent is 10%. 15. The medium of embodiment 5 wherein, in the method, the angular distribution of intensity conforms to a photogoniometer profile. 16. The medium of embodiment 5 wherein, in the method: the angular distribution has a maximum intensity; and the maximum intensity defines a pixel angle. 17. The medium of embodiment 16 wherein, in the method, the controlling includes varying the pixel angle over time.

‐ 84 ‐ 18. The medium of embodiment 17 wherein: the printer includes a collimating lens, a projector and an interface that defines a plane; and the method includes displacing the collimating lens, parallel to the plane, relative to the projector. 19. The medium of embodiment 18 wherein, in the method, the displacing includes moving the collimating lens in a pattern. 20. The medium of embodiment 18 wherein, in the method, the pattern is periodic. 21. The medium of embodiment 19 wherein, in the method, the pattern is linear. 22. The medium of embodiment 19 wherein, in the method, the pattern is elliptical. 23. The medium of embodiment 19 wherein, in the method, the pattern is periodic and has an amplitude of half a pixel diameter. 24. The medium of embodiment 17 wherein: the printer includes a collimating lens, a projector and an interface that defines a plane; and the method includes displacing the projector, parallel to the plane, relative to the collimating lens. 25. The medium of embodiment 1 wherein, in the method, the controlling comprises receiving a radiation instruction for each pixel, the radiation instruction corresponding to the beam characteristic. 26. The medium of embodiment 25 wherein, in the method, when there is defined in the lens body a series of predefined cross-sections in the lens body. 27. The medium of embodiment 25 wherein, in the method:

‐ 85 ‐ each cross-section is bound by a first surface and a second surface; the first surface corresponds to a first surface of the lens body; the second surface corresponds to a second surface of the lens body; and the first surface is defined in a signed distance field file. 28. The medium of embodiment 27 wherein the method further includes receiving a shape corresponding to the second surface of the lens body. 29. The medium of embodiment 28 wherein, in the method, the receiving a shape includes receiving a lens power value. 30. The medium of embodiments 27 wherein the method further comprises, when the signed distance field file is a first signed distance field file the receiving a shape includes receiving a second signed distance field file that defines the second shape. 31. The medium of embodiment 27 wherein: the printer includes a mask that is configured to block light from the projector that is outside of a perimeter; and the method further includes configuring the mask to conform, at each of the cross- sections, to: the first surface; and the second surface. 32. The medium of embodiment 27 wherein the method further includes configuring the mask to conform, at each of the cross-sections, to: a first edge between the first and second surfaces; and a second edge between the first and second surfaces. 33. The medium of embodiment 26 wherein: in the method, the radiation instructions are included in a stack of two- dimensional radiation instructions, each corresponding to one of the cross-sections; and the receiving includes receiving the stack.

‐ 86 ‐ 34. The medium of embodiment 33 wherein the method further includes receiving an aberration mitigation instruction that is configured to mitigate against structural defects resulting from radiation patterns of the pixels. 35. The medium of embodiment 34 wherein, in the method, the aberration mitigation instruction is registered to one of the cross-sections. 36. The medium of embodiment 35 wherein, in the method, the aberration mitigation instruction is one of a plurality of aberration mitigation instructions, each corresponding to a different one of the cross-sections. 37. The medium of embodiment 36 wherein: the printer includes a collimating lens and a projector; and, in the method, the aberration mitigation instruction corresponds to a relative motion of the collimating lens and the projector. 38. The medium of embodiment 36 wherein: the printer includes a collimating lens and a projector; and, in the method, the aberration mitigation instruction corresponds to an offset between a focal plane of light to be emitted from the projector and an incident surface of the collimating lens. 39. The medium of embodiment 33 wherein, in the method, the stack of two- dimensional radiation instructions are embodied in a Signed Distance Field (“SDF”) file. 40. The medium of embodiment 39 wherein, the SDF file is configured to be input into an optical lens milling machine. 41. The medium of embodiment 25 wherein, in the method, the controlling includes providing radiation to the resin in conformance with the radiation instruction. 42. The medium of embodiment 41 wherein, in the method, the controlling includes providing radiation to the resin in conformance with the SDF file.

‐ 87 ‐ 43. The medium of embodiment 34 wherein, in the method, the controlling includes providing radiation to the resin in conformance with: the radiation instruction; the aberration mitigation instruction; and the SDF file. PRE-GELATION ZONE THICKNESS—METHOD EMBODIMENTS 1. A method for forming an optical lens green body using a continuous vat polymerization printer, said continuous vat polymerization printer comprising a radiation source, said method comprising: projecting radiation from the radiation source through a first side of an interface layer; and curing resin on a second side of the interface layer, said second side opposite the first side, until a pre-gelation zone is formed, said pre-gelation zone comprising an initial curing zone proximal the interface layer and a shape-maintaining zone distal the interface layer; growing the pre-gelation zone to a thickness of 300 microns; maintaining the pre-gelation zone at not less than a thickness of 300 microns until the green body obtains a plurality of pre-determined dimensions. 2. The method of embodiment 1, wherein the plurality of pre-determined dimensions corresponds to a plurality of pre-determined optical lens precursor dimensions. 3. The method of embodiment 1, wherein the projection radiation from the radiation source comprising using a digital light processing (DLP. projector to project Ultra Violet (UV. light radiation upward through the interface layer. 4. The method of embodiment 1, wherein the projection radiation from the radiation source comprising using a digital light processing (DLP. projector to project Ultra Violet (UV. light radiation upward through the interface layer, and the UV light radiation is collimated by adding a collimating lens prior to the reaching the initial curing zone. 5. The method of embodiment 1, wherein the optical lens green body comprise two lenses formed together as a unitary component, wherein each of the two lenses

‐ 88 ‐ comprises a discrete prescription and a discrete eye center, each of said discrete eye centers that differs with respect to a distance from a center line of the unitary component. 6. The method of embodiment 5, wherein each of the two lenses is formed with connective apparatus for attachment to frame hardware. 7. The method of embodiment 1, wherein the projection radiation from the radiation source comprising using an array formed from a plurality of projectors, each of the plurality of projectors configured to project Ultra Violet (UV. light radiation upward through the interface layer. HARD COATING APPARATUS EMBODIMENTS 1. An optical lens comprising: a body layer that includes body layer moieties; and a coating layer that includes coating layer moieties; and a transition between the body layer and the coating layer; wherein: in the transition body layer moieties are covalently bonded to coating layer moieties. 2. The optical lens of embodiment 1, wherein the transition has a thickness of between 25 and 75 nanometers. 3. The optical lens of embodiment 1, wherein the transition has a thickness of about 50 nanometers. 4. The optical lens of embodiment 1, wherein the coating layer is an anti- reflective (“AR”) layer. 5.. The optical lens of embodiment 1, wherein the coating layer is an anti- abrasive layer. 6. The optical lens of embodiment 1, wherein a first coating layer is applied prior to a post-print curing step. 7. The optical lens of embodiment 6, wherein a second coating layer is applied after a post-print curing step.

‐ 89 ‐ 8. The optical lens of embodiment 6, wherein a second coating layer is applied after a polishing step. 9. The optical lens of embodiment 1, wherein the coating layer is applied using a spin-coating method. 10. The optical lens of embodiment 1, wherein the coating layer is applied using a dip-coating method. 11. The optical lens of embodiment 1, wherein the coating layer is non-index matching. 12. The optical lens of embodiment 1, wherein the coating layer is applied using Ultra Violet (UV) radiation. HARD COATING METHOD EMBODIMENTS 1. A method for coating a body layer of an optical lens, said body layer comprising body layer moieties, said method comprising: curing the body layer of the optical lens to less than a complete cure; placing the body layer in an environment in which coating layer material for forming a coating layer is present, said coating layer material comprising coating layer moieties; using radiation to covalently bond the body layer to the coating layer, wherein, in response to the using radiation, a transition between the body layer and the coating layer is formed; wherein: in the transition, body layer moieties are covalently bonded to coating layer moieties. 2. The method of embodiment 1, wherein the transition has a thickness of between 25 and 75 nanometers. 3. The method of embodiment 1, wherein the transition has a thickness of about 50 nanometers. 4. The method of embodiment 1, wherein the coating layer is an anti- reflective (“AR”) layer. 5. The method of embodiment 1, wherein the coating layer is an anti- abrasive layer.

‐ 90 ‐ 6. The method of embodiment 1, wherein a first coating layer is applied prior to a post-print curing step. 7. The method of embodiment 6, wherein a second coating layer is applied after a post-print curing step. 8. The method of embodiment 6, wherein a second coating layer is applied after a polishing step. 9. The method of embodiment 1, wherein the coating layer is applied using a spin-coating method. 10. The method of embodiment 1, wherein the coating layer is applied using a dip-coating method. 11. The method of embodiment 1, wherein the coating layer is non-index matching. 12. The method of embodiment 1, wherein the coating layer is applied using Ultra Violet (UV) radiation.

‐ 91 ‐

Claims

WHAT IS CLAIMED IS: 1. An optical lens comprising: a body layer that includes body layer moieties; and a coating layer that includes coating layer moieties; and a transition between the body layer and the coating layer; wherein: in the transition body layer moieties are covalently bonded to coating layer moieties. 2. The optical lens of embodiment 1, wherein the transition has a thickness of between 25 and 75 nanometers. 3. The optical lens of embodiment 1, wherein the transition has a thickness of about 50 nanometers. 4. The optical lens of embodiment 1, wherein the coating layer is an anti- reflective (“AR”) layer. 5.. The optical lens of embodiment 1, wherein the coating layer is an anti- abrasive layer. 6. The optical lens of embodiment 1, wherein a first coating layer is applied prior to a post-print curing step. 7. The optical lens of embodiment 6, wherein a second coating layer is applied after a post-print curing step. 8. The optical lens of embodiment 6, wherein a second coating layer is applied after a polishing step. 9. The optical lens of embodiment 1, wherein the coating layer is applied using a spin-coating method. 10. The optical lens of embodiment 1, wherein the coating layer is applied using a dip-coating method. 11. The optical lens of embodiment 1, wherein the coating layer is non-index matching. 12. The optical lens of embodiment 1, wherein the coating layer is applied using Ultra Violet (UV) radiation.

‐ 92 ‐ 13. A method for coating a body layer of an optical lens, said body layer comprising body layer moieties, said method comprising: curing the body layer of the optical lens to less than a complete cure; placing the body layer in an environment in which coating layer material for forming a coating layer is present, said coating layer material comprising coating layer moieties; using radiation to covalently bond the body layer to the coating layer, wherein, in response to the using radiation, a transition between the body layer and the coating layer is formed; wherein: in the transition, body layer moieties are covalently bonded to coating layer moieties. 14. The method of embodiment 1, wherein the transition has a thickness of between 25 and 75 nanometers. 15. The method of embodiment 1, wherein the transition has a thickness of about 50 nanometers. 16. The method of embodiment 1, wherein the coating layer is an anti- reflective (“AR”) layer. 17. The method of embodiment 1, wherein the coating layer is an anti- abrasive layer. 18. The method of embodiment 1, wherein a first coating layer is applied prior to a post-print curing step. 19. The method of embodiment 18, wherein a second coating layer is applied after a post-print curing step. 20. The method of embodiment 18, wherein a second coating layer is applied after a polishing step. 21. The method of embodiment 1, wherein the coating layer is applied using a spin-coating method. 22. The method of embodiment 1, wherein the coating layer is applied using a dip-coating method. 23. The method of embodiment 1, wherein the coating layer is non-index matching.

‐ 93 ‐ 24. The method of embodiment 1, wherein the coating layer is applied using Ultra Violet (UV) radiation. 25. A non-transitory computer-readable medium storing instructions for producing an optical lens body, that when the instructions are executed by a continuous vat polymerization printer cause the continuous vat polymerization to perform a method comprising: projecting radiation into a resin; drawing a gel body away from a projector that provides the radiation; and controlling a thickness of a pre-gelation zone extending from the resin to the gel body. 26. A non-transitory computer-readable medium storing instructions for producing an optical lens body, that when the instructions are executed by a continuous vat polymerization printer cause the continuous vat polymerization to perform a method comprising: projecting pixelated radiation into a resin; drawing a gel body away from a projector that provides the radiation; and controlling a beam characteristic of each pixel in the pixelated radiation. 27. A method for forming an optical lens green body using a continuous vat polymerization printer, said continuous vat polymerization printer comprising a radiation source, said method comprising: projecting radiation from the radiation source through a first side of an interface layer; and curing resin on a second side of the interface layer, said second side opposite the first side, until a pre-gelation zone is formed, said pre-gelation zone comprising an initial curing zone proximal the interface layer and a shape-maintaining zone distal the interface layer; growing the pre-gelation zone to a thickness of 300 microns; maintaining the pre-gelation zone at not less than a thickness of 300 microns until the green body obtains a plurality of pre-determined dimensions.

‐ 94 ‐