A technique is provided for manufacturing eyepieces for a head mounted display by forming the eyepiece in two parts: a coated, smaller insert part with a first coating (e.g. chiolite), and a second, larger supporting part with an opening or gap for the coated smaller part. The inset and supporting parts are formed from an eyepiece material via injection molding, and the inset part is then coated with the first coating. The inset is inserted into the gap of the supporting part, and the two parts are cast with an index matching material. The casting forms a front and back shell around the eyepiece, and also bonds the two parts together. By forming the lens in this way, the amount of material used in eyepiece formation is reduced. Further, the formation of ophthalmic lenses is simplified.
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Shi, Hongqin and Tung, Yeh-Jiun, "Injection Molding Eyepieces for Head Mounted Display", Technical Disclosure Commons, (December 07, 2017)