06.03.2025

Nearsightedness (myopia) is becoming increasingly common worldwide, especially among children and adolescents. Researchers at the Fraunhofer Institute for Microstructure of Materials and Systems IMWS have developed a process called laser swelling, which enables the cost-effective and customized production of microlenses for eyeglasses.

Image: The image shows a microscopic close-up of a structured surface with spherical microlenses; copyright: Fraunhofer IMWS

Laser swelling forms microlenses on spectacle lenses by targeted laser irradiation of the plastic.

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Currently, around 33 percent of children and adolescents worldwide are nearsighted, and studies suggest this number could rise by 2050. The long-term consequences of myopia include an increased risk of retinal detachment, cataracts, and macular degeneration, leading to significant vision impairment.

Specialized eyeglasses with microlenses have been developed to slow the progression of nearsightedness. By creating a peripheral focal point, these lenses reduce the elongation of the eyeball, which is the primary cause of myopia progression.

Laser swelling: precision and cost-efficiency in microlens production

Fraunhofer IMWS has introduced laser swelling, a technique that directly forms microlenses on eyeglass lenses. This method involves directing a focused infrared laser onto plastic materials used in eyeglasses. The laser acts as a localized heat source, stimulating water molecules within the polymer. The movement of these molecules generates internal pressure, creating a controlled surface bulge that remains after treatment - forming a microlens.

Advantages of the laser swelling process:

Precision: The laser can be positioned with high accuracy, allowing the creation of ultra-small microlenses.

Customization: Microlenses can be arranged flexibly to meet individual needs.

Cost-Effectiveness: Unlike traditional injection molding, laser swelling is a contact-free process that eliminates the need for expensive tools.

Environmental Benefits: No material is removed, preventing microplastic waste.

“The laser beam can be positioned with great accuracy on surfaces, so we can produce significantly smaller microlenses than is possible with previously existing methods,” explains Prof. Thomas Höche, initiator of the technology and head of the Optical Materials and Technologies business unit at Fraunhofer IMWS.

Wide-ranging applications in medical technology

Beyond the eyeglass industry, Fraunhofer IMWS envisions various applications for laser swelling:

Microlenses for intraocular lenses used in cataract treatments

Optimization of microfluidic components

Enhanced adhesion properties for polymer surfaces

Miniaturized, high-performance microscopes

Discreet marking of medical products, such as syringes with tracking codes for authentication

“Laser swelling also gives us a lot of flexibility in terms of the size and shape of the microlenses. From spherical to aspheric and even cylindrical lenses, anything is possible,” Höche says.

Fraunhofer IMWS has applied for global intellectual property rights and is currently working on the commercialization of this technology. While the focus remains on the eyeglass industry, laser swelling holds potential for numerous other applications.

“Corrective eyewear that can be tailored individually to the needs of certain occupational groups is our vision,” says Höche.

COMPAMED-tradefair.com; Source: Fraunhofer-Gesellschaft

More about the Fraunhofer-Gesellschaft at: www.fraunhofer.de/en