A method of forming an optical element which includes an electrochromic apodized aperture having variable light transmittance through a clear aperture area in response to an applied electrical current is disclosed. The apodized aperture includes a body including an area defining the clear aperture area wherein a fluid containment area substantially overlapping the clear aperture area, and includes at least one fill passage extending from the fluid containment area to at least one fill port outside of the clear aperture area; an electrochromic fluid within the fluid containment area substantially overlapping the clear aperture area and having variable light transmittance in response to an applied electrical current; a cover attached with the electrochromic fluid between the cover and body; electrical contacts electrically coupled to the electrochromic fluid for supplying electrical current thereto; and at least one passage seal in each said fill passage positioned outside of the clear aperture area.