Progressive Design

in the Digital Age

-Pete Hanlin, ABOM

Overview
Importance of the Design

Potential of the DS Process

Design Formats & Capabilities

Introducing
Introducing
Importance of the Design
Design is everything!
...poor design leads to poor
performance...
(Somehow, designer forgot to leave
his name on the base...)
Importance of the Design
New processing technologies
do enhance great designs...

...but they cannot make an

average design exceptional!
Importance of the Design
There are several fundamentals a PAL design
must provide- to name a few:
–Natural Reading Posture (rate of progression)

–Properly Placed Near Zone (correct inset)

–Binocularity (balanced peripheral vision)

–Central Focus (sharp vision in all zones)

Natural Reading Posture
Natural reading posture characteristics:
Head tilts down 40°
Eyes vertically scan 15°
PALs should require at most 25° downward gaze
No Eyewear Non-Optimal PAL Optimal PAL
Natural Reading Posture
The ideal progression length is around
12mm to 85% of the ADD power
>12mm requires eye to look downward >25°
<12mm increases peripheral astigmatism

Patent FR 2 699 294 "...a very low sphere gradient for a

so short power progression and a maximum gradient
value located in the intermediate vision zone"
Properly Placed Near Zone
The near zone must be optimally placed
Convergence inset is determined by:
Prismatic effects of the Rx
Convergence required at focal length of ADD

Patent FR 2 683 643 "...a near zone which gets higher and
more nasally decentered with the increase of the addition"

0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50
BASE ONE 1.81 1.92 1.98 2.09 2.29 2.29 2.29 2.29 3.05 3.05 3.05 3.05
BASE TWO 1.94 2.03 2.09 2.09 2.29 2.29 2.29 2.29 3.05 3.05 3.05 3.05
BASE THREE 2.09 2.09 2.09 2.09 2.29 2.29 2.29 2.29 3.05 3.05 3.05 3.05
BASE FOUR 2.69 2.71 2.72 2.74 2.80 2.95 3.11 3.21 3.51 3.72 3.90 4.10
BASE FIVE 2.92 2.94 2.97 2.99 3.00 3.04 3.29 3.39 3.70 3.90 4.17 4.30
Binocularity
The optics of a PAL must be similar in every
viewing position
The eyes must work together to maintain
stereopsis (depth perception)
Binocularity
Even low levels of astigmatism will disrupt
vision if it is imbalanced
The visual system can handle peripheral
aberration- as long as it binocularly equivalent

Dissimilar Similar

Patent EP 0 994 375 "...a very low difference in sphere for two corresponding
points of the right and left lenses, and this for all points of the space"
Central Focus
The central zones of the lens must provide
sharp focus
Astigmatism is usually located in the periphery
Higher order aberrations (HOAs) reduce
sharpness in the central zones of a PAL
Central Focus
Control of the wavefront results in the
sharpest possible central vision
W.A.V.E. Technology™ provides clinically
proven improvements in vision
Varilux Physio Comp A Comp B

Patent FR 05 07378 "In a wide angular zone (150 to 160) with a vertex 4 below
the fitting cross, the high order aberrations, including coma, are reduced,
allowing a clear far vision zone. At the same time, the near vision zone is
easily accessible at 25 of gaze excentricity downward"
Importance of the Design
ALL of the fundamentals of design can be
delivered by ANY processing format:
Traditional Surfacing
Digital Surfacing
Potential of Digital Surfacing
Limitations of
Traditional Surfacing
• Tooling required for each shape
(designer is limited by # of tools)
• Tooling limits accuracy of lens
• Only one surface can be used for
the progressive design
Solutions of
Digital Surfacing
• Tool can create unlimited shapes
(designer is not limited by tools)
• Tool is exceptionally accurate*
• Both surfaces can be used for the
progressive design
How Digital Surfacing Works
A DS generator is similar to a lathe

Lens starts as a block ...a single point cutter ...finished surface can
of material... removes material from be virtually any shape-
the spinning blank to with the potential for
create a 3D surface... great precision.

In digital surfacing, the cutter is precisely controlled by motors which

follow a path contained in the form of a computerized (digital) file.
Increased Tool Capability
Traditional Surfacing is limited by physical tools
Molds for complex front surfaces
Laps/Tools for simple back surfaces
Digital Surfacing uses "digitized" tools (digital files)
A virtually unlimited number of shapes can be produced
Designer is free to create an ∞ number of surfaces

Distance Power and/or

Progressive Design

Progressive Distance
Design Power
Increased Tool Capability
The impact of DS capability is limited by:
the quality of the initial design
the ability to create meaningful customization
Otherwise, digital surfacing is just another way to
make a lens

=
Increased Precision
The DS process is capable of greater
precision than traditional surfacing

+  DISTANCE POWER  -
TRADITIONAL SURFACING Digital Surfacing
+/-0.12D

+/-0.06D

-  DESIGN  + -  DESIGN  +

Traditional tooling creates Digital tooling can be accurate to

"rounding errors" which cause up within 0.01D of target powers
to 0.06D of distance power error
Increased Precision
DS processes must be tightly controlled
UNCONTROLLED UNCONTROLLED

+  DISTANCE POWER  -
TRADITIONAL SURFACING DIGITAL SURFACING

-  DESIGN  + -  DESIGN  +

Process variations usually affect When DS is used to create a

only the distance power of PAL design, process variations
traditionally surfaced lenses. will affect the design
"6x more accurate"
DS potentially has greater accuracy- but it is harder
to control.
Essilor has invested
millions in DS process
R&D, because an
uncontrolled DS
process produces
unreliable product!
Increased Precision
Essilor has > 20 years invested in DS R&D
Essilor Digital Surfacing Process Control (DSPC) is a
complete quality assurance system
every laboratory required to test/calibrate processes daily
A "DS PAL" = design + process
If the process is bad, the design will not be accurate
All major manufacturers have a defined process

DSPC
 Digital Surfacing Process Control
DEPARTMENT MANAGER
E. COMTE
Assistant
M.HAGER

SURFACING MANAGER SURFACING MANAGER

SURFACING MANAGER CALCULATION B.GELB W.MAYUREE (TOY)
T. BAUDART

INDUSTRIALIZATION
B.TAYLOR P.WASANCHAI
PRODUCTS TECHNO
WORKSHOP INDUSTRIALIZATION (TA)
INDUSTRIALIZATION
L.GRELICHE B.GODEAU G.MARTIN J-L. ARBESSIER B.BEESON
C.PETCHARAT
TECHNICAL LEADER TECHNICAL LEADER (Poy)
BLOCKING MACHINING/POLISHING M.MODH
M.LE GALL X. BULTEZ
B. ROMAIN D. DRUGEON
K.SANRAYU
(JOY)
J.SHERIDAN
Y.FELTEN
D.BOULET
M. METTEL C.ING ON
J. CONCIALDI
M.KALUZA (ING)

PH.CORNE JF. BELLY

T.NIDA
N. BELHACHMI
P.RENAUD (KERNG)
Apprenti
G.BOLTEAU
S.PICHOUX
K.SCHROWANGEN K.PHANUWAT
F. GAUCHI-MARTINO
Y.DUPIN (JO)
Intérimaire
M.DURANT B.CALLIER J.MONAGHAN
K.CHETTHAPHON
V. MARTIN
(EARTH)
Conges 18 mois
M.JACOB
P.DEMION M.LIBBRECHT
I. KATESANEE
T. TOVEY (KATE)
J. DE BARROS
N. FARIA
S. WEERAPON
B. LYONS (MAN)

S.SPOHR F.LAFON
H. NGUYEN
A. SAUZE
CRETEIL Apprentice
DALLAS BANGKOK
OUDRY
 D = Design d = distance

Increased Design Flexibility

power

Traditional surfacing is limited to one design

Design (D) placed on the front surface
Distance power (d) surfaced on the back
Playing music through a single speaker system
limits the ability to design sound effects...

D d

Using only one surface for progressive design

Traditional PAL
also limits the effects the designer can create...
 D = Design d = distance

Increased Design Flexibility

power

FBS PALs are also limited to one design

Design (D) placed on the back surface
Distance power (d) surfaced on the back
The location of the speaker is changed...

D d

...and the flexibility of DS does allow the designer

FBS (DRx™)
to customize to a limited degree
 D = Design d = distance

Increased Design Flexibility

power

Digital surfacing can support two designs

Designs (D) are placed on both surfaces
Distance power (d) is digitally surfaced on back
Two speakers makes it possible to create stereo
and other sound effects...

d
D
D
Using two surfaces makes it possible for the
DualOptix™
designer to create new optical effects...
Increased Design Flexibility
Two designs allow the designer to address
both defocus and distortion simultaneously

Management of Distortion

Patient's Blurred Vision Controlled Correction

A single surface can control Two surfaces can be used

focus or distortion (usually to control focus &
a compromise of the two) distortion simultaneously...
Management of Focus
Increased Design Flexibility
An example of two-surface design:
Rx -1.00 sph / +3.00 ADD

6B -1.00 6B -1.00 6B -1.00

d d
D d D
D D

9B +2.00 6B +2.00 7B +2.00

TRADITIONAL FBS (DRx™) DualOptix™
Single surface progressions cannot provide the optimal curvature for both
the distance and the near powers (and asphericity alone cannot overcome
all "base curve effects"). Disassociating the power change from the
curvature change reduces distortion to levels not otherwise possible.
Review
Digital surfacing provides three advantages
Removes tooling limitations
but customization must be meaningful
Potential for greater precision
but the process must be controlled
Allows designer to use both sides of the lens
allows simultaneous control of focus and distortion
 D = Design d = distance

New PAL Formats

power

Traditional PAL
• A single surface PAL
D d • Design on front
• Distance power on back
• Compromise between control of focus / distortion

DRx™ (FBS) PAL

d • A single surface PAL
• Design on back
• Distance power on back
D • Greater accuracy
• Compromise between control of focus / distortion
DualOptix™ PAL
d • A two-surface PAL
• Designs on front & back
D • Distance power on back
D • Greater accuracy
• Control of both focus / distortion
Advantages of DS Formats
Benefits of both FBS and DualOptix™
More precise compared to Traditional PALs
Additional Benefit of DualOptix™
Control of both focus and distortion

Essilor uses the DualOptix format for

d d customization- since it offers the
greatest ability to control focus and
D distortion.
D D
FBS DualOptix™
Types of DualOptix Customization ™

Personalization to Head/Eye Ratio (Varilux Ipseo IV)

W.A.V.E. Technology 2 (Varilux Physio Enhanced)
Maximized Zone Width (Varilux Comfort Enhanced/All Varilux)
DUAL ADD TECHNOLOGY (DEFINITY)
FrameOptimization Technology (Accolade Freedom)
Additional benefits common to ALL DualOptix PALs
Atoricity (to reduce peripheral aberration)
Customized Near Zone Inset (to promote reading)
Customized to Fitting Height d
Length of Progression D
Distribution of Zones (wider distance angle)
D
DS Design Capabilities
DEFINITY- reduces astigmatism/distortion
Widest Intermediate
Least Swim
Varilux Physio Enhanced- customized wavefront
Sharpest Vision Possible
New Varilux Comfort Enhanced- peripheral width
Wide/Smooth Vision
Accolade Freedom- instant adaptation
95% adaption in first 5 minutes
Benefits of DualOptix PALs
Varilux Ipseo IV is the only PAL featuring a
DualOptix design which adapts to the wearer's
individual visual strategy
the design is individualized to 7 parameters
wavefront correction pupil map
sphere slope management
position of wear
visual zone width
distance Rx atoricity
progression length
zone distribution
Benefits of DualOptix PALs
Varilux Physio Enhanced is the only PAL providing
customized wavefront correction
W.A.V.E. Technology 2 personalizes the design to 4 parameters
wavefront correction pupil map
distance Rx atoricity
progression length
zone distribution

customized
wavefront correction wavefront correction

pupil size
Benefits of DualOptix PALs
DEFINITY is the only PAL to split addition to
achieve levels of astigmatism not possible in a
single surface PAL
DUAL ADD TECHNOLOGY customizes the design to 2 parameters
distance Rx atoricity
progression length
Conclusions
The foundations of PAL design can be
delivered in ANY format
Two new DS formats are available:
DRx™
greater precision than traditional PALs
DualOptix™
greater precision than traditional PALs
unlimited ability to customize