Method of making an ocular implant

Abstract

A method of making a mask configured to improve the depth of focus of an eye of a patient is provided. A substrate with a mask forming feature is provided. The mask forming feature comprises a forming surface that extends from an outer periphery. The forming surface is centered on a central axis of the mask forming feature. A release layer is formed on the forming surface. A mask layer is formed such that the release layer is between the mask layer and the substrate. The mask layer is formed of a biocompatible metal. A surface of the mask layer opposite the release layer is configured to not corrode. The mask layer is separated from the substrate.

1 . A method of making a mask configured to improve the depth of focus of an eye of a patient, the method comprising: 
 providing a substrate with a mask forming feature comprising a forming surface extending from an outer periphery, the forming surface being centered on a central axis of the mask forming feature, the forming surface having a curved profile corresponding to the curvature of a corneal layer of the eye;    forming a mask layer of a biocompatible metal on the substrate;    configuring a surface of the mask layer to not corrode; and    separating the mask layer from the substrate.    
   
   
       2 . The method of  claim 1 , further comprising forming a non-reflective layer on the mask layer to darken the appearance of the mask.  
   
   
       3 . The method of  claim 2 , wherein the biocompatible metal is a noble metal and the non-reflective layer comprises a carbon layer.  
   
   
       4 . The method of  claim 1 , wherein forming further comprises forming at least a portion of the mask layer of a titanium alloy.  
   
   
       5 . The method of  claim 4 , wherein the titanium alloy exhibits super-elastic characteristics.  
   
   
       6 . The method of  claim 4 , wherein the titanium alloy is nitinol.  
   
   
       7 . The method of  claim 4 , wherein the titanium alloy comprises nickel and titanium.  
   
   
       8 . The method of  claim 4 , wherein the mask layer is a first layer, and configuring further comprises forming a second mask layer of a second material that does not react chemically with the titanium alloy.  
   
   
       9 . The method of  claim 8 , wherein the second material is titanium oxide.  
   
   
       10 . The method of  claim 8 , wherein the second material is silicon carbide.  
   
   
       11 . The method of  claim 1 , wherein the surface of the mask is configured to not corrode by forming the mask layer of a biocompatible metal that does not corrode when implanted in the body.  
   
   
       12 . The method of  claim 1 , wherein forming the mask layer further comprises forming at least a portion of the mask layer of gold.  
   
   
       13 . The method of  claim 1 , wherein forming the mask layer further comprises forming at least a portion of the mask layer of palladium.  
   
   
       14 . The method of  claim 1 , wherein forming the mask layer further comprises forming at least a portion of the mask layer of platinum.  
   
   
       15 . The method of  claim 1 , wherein forming the mask layer further comprises forming at least a portion of the mask layer of tantalum.  
   
   
       16 . The method of  claim 1 , wherein forming the mask layer further comprises forming at least a portion of the mask layer of titanium.  
   
   
       17 . The method of  claim 1 , wherein forming the mask layer further comprises sputtering the mask layer.  
   
   
       18 . The method of  claim 1 , wherein forming the mask layer further comprises electro-depositing the mask layer.  
   
   
       19 . The method of  claim 1 , wherein the forming surface is an annular surface that extends from the outer periphery to an inner periphery of the mask forming feature.  
   
   
       20 . The method of  claim 1 , further comprising removing a central portion of the mask layer to form an aperture in the mask layer.  
   
   
       21 . A method of making a mask configured to improve the depth of focus of an eye of a patient, the method comprising: 
 providing a substrate with a mask forming feature comprising a forming surface centered on a central axis of the mask forming feature;    forming a release layer on the forming surface;    forming a mask layer of a biocompatible metal such that the release layer is between the mask layer and the substrate;    configuring a surface of the mask layer opposite the release layer to not corrode; and    separating the mask layer from the substrate.    
   
   
       22 . A method of making a mask configured be implanted in a cornea of an eye of a patient to improve the depth of focus of the patient, the mask being disposed about a visual axis of the eye extending through a pupil of the eye when applied, the method comprising: 
 providing a substrate with a mask forming feature comprising an annular surface extending between an inner periphery and an outer periphery, the annular surface being centered on a central axis of the mask forming feature;    forming at least a portion of the mask by depositing a mask layer of a biocompatible metal on the substrate;    configuring the mask to be inert; and    separating the mask layer from the substrate.    
   
   
       23 . The method of  claim 22 , wherein the mask is configured to be inert by forming the mask layer of a noble metal.  
   
   
       24 . The method of  claim 22 , further comprising forming a cosmetic layer on an anterior surface of the mask such that the anterior surface blends in with the pupil.  
   
   
       25 . The method of  claim 24 , wherein the biocompatible metal is a noble metal and the cosmetic layer is carbon.  
   
   
       26 . The method of  claim 22 , wherein the mask is configured to be inert by forming a cosmetic layer on an anterior surface of the mask layer, at least one of the mask layer and the cosmetic layer being selected such that there is substantially no galvanic potential between the mask layer and the cosmetic layer.  
   
   
       27 . The method of  claim 26 , wherein the mask layer is formed of an alloy comprising nickel and titanium and the cosmetic layer is formed of silicon carbide.  
   
   
       28 . The method of  claim 26 , wherein the mask layer is formed of an alloy comprising nickel and titanium and the cosmetic layer is formed of titanium oxide.  
   
   
       29 . The method of  claim 22 , wherein forming the mask layer further comprises sputtering the mask layer.  
   
   
       30 . The method of  claim 22 , wherein forming the mask layer further comprises electro-depositing the mask layer.  
   
   
       31 . The method of  claim 22 , wherein forming comprises forming the mask layer with a plurality of pores.  
   
   
       32 . The method of  claim 31 , further comprising configuring the substrate to cause pore formation when the mask layer is formed.  
   
   
       33 . The method of  claim 31 , wherein the mask layer is formed by electro-deposition and the density of pores is a function of an electro-deposition rate.  
   
   
       34 . The method of  claim 22 , wherein the substrate includes a plurality of mask forming features and forming the mask layer further comprises forming at least a portion of a first mask and at least a portion of a second mask.  
   
   
       35 . The method of  claim 34 , further comprising separating the first mask portion from the second mask portion.  
   
   
       36 . A mask configured to improve the depth of focus in an eye of a patient comprising: 
 a posterior layer formed of a biocompatible metal; and    a cosmetic layer.    
   
   
       37 . The mask of  claim 36 , wherein the cosmetic layer is a non-reflective layer  
   
   
       38 . The mask of  claim 37 , wherein the cosmetic layer darkens the appearance of the mask.  
   
   
       39 . The mask of  claim 36 , wherein the biocompatible metal is a noble metal and the cosmetic layer comprises a carbon layer.  
   
   
       40 . The mask of  claim 36 , wherein the biocompatible metal comprises a titanium alloy.  
   
   
       41 . The mask of  claim 40 , wherein the titanium alloy exhibits super-elastic characteristics.  
   
   
       42 . The mask of  claim 40 , wherein the titanium alloy is nitinol.  
   
   
       43 . The mask of  claim 40 , wherein the titanium alloy comprises nickel and titanium.  
   
   
       44 . The mask of  claim 40 , wherein the posterior layer is a first layer, and the cosmetic layer is formed of a material that does not react chemically with the titanium alloy.  
   
   
       45 . The mask of  claim 44 , wherein the cosmetic layer comprises titanium oxide.  
   
   
       46 . The mask of  claim 44 , wherein the cosmetic layer comprises silicon carbide.  
   
   
       47 . The mask of  claim 36 , wherein the posterior layer is formed of a biocompatible metal that does not corrode when implanted in the body.  
   
   
       48 . The mask of  claim 36 , wherein the posterior layer comprises gold.  
   
   
       49 . The mask of  claim 36 , wherein the posterior layer comprises palladium.  
   
   
       50 . The mask of  claim 36 , wherein the posterior layer comprises platinum.  
   
   
       51 . The mask of  claim 36 , wherein the posterior layer tantalum.  
   
   
       52 . The mask of  claim 36 , wherein the posterior layer comprises titanium.