A method of forming a three-dimensional object (e.g. comprised of polyurethane, polyurea, or copolymer thereof) is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid comprising a mixture of: (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the second solidifiable component; and then (d) contacting the three-dimensional intermediate to water to form the three-dimensional object.

A soft mold tool including an elastomeric material; and a photomask; wherein the photomask is positioned within the elastomeric material is disclosed. Additionally, a soft mold tool, including an elastomeric material; and an opaque material on a portion of a surface of the elastomeric material is disclosed. A method of making the soft mold tool is also disclosed.

An integrally formed resin diffusing component (100), a diffractive optical element (DOE), and a manufacturing method thereof. A resin material (630) in a liquid is spread between a supporting plate (610) and a mold (620) of a manufacturing apparatus (600), pressed, and light-cured, thus producing the light-cured resin diffusing component (100) or the DOE. The diffusing component (100) or the DOE is integrally formed, the phenomenon of delamination is prevented from occurring, and the need for high-temperature injection molding and cooled forming is obviated.

A high-performance optical absorber, having a texturized base layer, the base layer comprising one or more of a polymer film and a polymer coating; and a surface layer located above and immediately adjacent to the base layer. The surface layer is joined to the base layer and the surface layer has a plasma-functionalized, non-woven carbon nanotube (CNT) sheet, wherein the base layer texturization comprises one or more of substantially rectangular ridges, substantially triangular ridges, substantially pyramidal ridges, and truncated, substantially pyramidal ridges.

Lighting systems are described. A lighting system includes a first lead frame portion and a second lead frame portion. The first lead frame portion has at least a top surface, a bottom surface, and an opening. The second lead frame portion is within the opening of the first lead frame portion and has at least a top surface and a bottom surface. Light-emitting diode (LED) devices are each mechanically and electrically coupled to the top surface of the first lead frame portion and the top surface of the second lead frame portion. An electrically insulating and optically reflective material is disposed over exposed regions of the top surfaces of the first and second lead frame portions.

A method of forming a three-dimensional object is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid including a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid polymer scaffold from the first component and also advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, and containing the second solidifiable component carried in the scaffold in unsolidified and/or uncured form; and (d) concurrently with or subsequent to the irradiating step, solidifying and/or curing the second solidifiable component in the three-dimensional intermediate to form the three-dimensional object.

An optical component has a small-volume section and a large-volume section, wherein said optical component is a single-piece injection-molded component with the exception of one region in the large-volume section, said component being supplemented, in the region in the large-volume section, by an add-on to the optical component.

Examples of an imaging system for use with a head mounted display (HMD) are disclosed. The imaging system can include a forward-facing imaging camera and a surface of a display of the HMD can include an off-axis diffractive optical element (DOE) or hot minor configured to reflect light to the imaging camera. The DOE or hot minor can be segmented, for example, with different segments having different angles or different optical power. The imaging system can be used for eye tracking, biometric identification, multiscopic reconstruction of the three-dimensional shape of the eye, etc. Methods for manufacturing angularly segmented optical elements are also provided. The methods can include injection molding.

Bus bar configurations and fabrication methods for non-rectangular shaped (e.g., triangular, trapezoidal, circular, pentagonal, hexagonal, arched, etc.) optical devices.

Systems and methods to manufacture a collimator include deposition of a first layer of material in a first pattern, the first pattern comprising a first plurality of substantially parallel lines oriented in a first direction, and deposition of a second layer of material in a second pattern directly upon the first layer of material, the second pattern comprising a second plurality of substantially parallel lines oriented in a second direction different from the first direction. An area bounded by a first pair of the first plurality of substantially parallel lines and a second pair of the second plurality of substantially parallel lines intersecting the first pair defines a septum of the collimator.