Method and manufacturing complex optical designs in soft...

Details Method and manufacturing complex optical designs in soft... Method and manufacturing complex optical designs in soft...

B - Operations, Transporting

29

D

B29D 11/00 (2006.01)

Patent

CA 2233556

The method includes: (a) automatically generating a cnc machine code data set for machining a contact lens mold insert to define a complex optical surface thereon; (b) machining a plurality of the contact lens mold inserts with the cnc data set with a single diamond point lathe, the lathe having sub-micron precision and repeatability; (c) simultaneously molding a first plurality of contact lens mold halves with the contact lens mold inserts to define the complex optical surface on the plurality of first mold halves; (d) molding a second plurality of contact mold halves to cooperate with the first plurality of mold halves wherein a single first mold half and a single second mold half cooperate to define a mold space for a soft contact lens therebetween; (e) assembling the first plurality of hold halves with the second plurality of mold halves with a polymerizable monomer therebetween; and (f) polymerizing the monomer to form a plurality of soft contact lenses having a complex optical surface. This method enables to create repeatable mold inserts having complex optical shapes or curves formed therein which enable formation of intermediate mold halves and soft contact lenses having micron range transitions between optical surfaces.

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