Design and fabrication of a freeform phase plate for high-order ocular aberration correction

In recent years it has become possible to measure and in some instances to correct the high-order aberrations of human eyes. We have investigated the correction of wavefront error of human eyes by using phase plates designed to compensate for that error. The wavefront aberrations of the four eyes of two subjects were experimentally determined, and compensating phase plates were machined with an ultraprecision diamond-turning machine equipped with four independent axes. A slow-tool servo freeform trajectory was developed for the machine tool path. The machined phase-correction plates were measured and compared with the original design values to validate the process. The position of the phase-plate relative to the pupil is discussed. The practical utility of this mode of aberration correction was investigated with visual acuity testing. The results are consistent with the potential benefit of aberration correction but also underscore the critical positioning requirements of this mode of aberration correction. This process is described in detail from optical measurements, through machining process design and development, to final results.