Systems, devices, and methods are disclosed for fabricating a hybrid contact lens product having a lens insert embedded at a precisely controlled location within a lens body. A mold engagement and support base engages and retains a lens forming mold in a substantially fixed position. An insert placement and positioning device includes an insert pickup head with a contact face configured for releasable engagement of the lens insert and at least one suction opening in the contact face for applying suction to engage the insert on the contact face. A positioning housing interacts with the mold and/or the support base to provide precise locational positioning of the lens insert within the mold. A lens body forming material is delivered to the mold to encapsulate the lens insert.

The present invention relates to systems and methods for forming a lens having a concave surface with at least one undercut. In one embodiment, the lens has a concave surface with at least one undercut. For example, a pliable lens with undercuts can be formed by using a pliable moldable material injected into a mold have a negative profile with at least one protrusion corresponding to an undercut of a target pliable lens. The pliable curved textured lens can now be peeled away from the mold after the shaped profile of the target pliable lens is set.

Apparatus and methods are described for manufacturing contact lenses employing dissolvable mold structure. The apparatus and methods involve approaches to dissolve at least portions of a mold and to separate a lens from the mold to present the lens for collection.

A resin amount for forming each first-stage resin layer portion (a first-stage resin replica portion) 41da in a first process is defined to be greater than a resin amount for forming each second-stage resin layer portion (a second-stage resin replica portion) 41db in a second process. Therefore, at a boundary between the first-stage resin layer portion 41da and the second-stage resin layer portion 41db, a joint portion 48 at which resin overlaps is formed, whereby occurrence of an undercut shape can be avoided. Therefore, in a molding process using a sub-master die 40 and a sub-sub-master die 50 obtained from the sub-master die 40, occurrence of an undesired shape can be avoided, whereby mold release resistance can be reduced or eliminated.

An optical device includes a center section having a lens portion for modifying distribution of a first part of light emitted by a light source, and a peripheral section surrounding the center section and including a conical surface for modifying distribution of a second part of the light emitted by the light source. The conical surface includes ridges where total internal reflection takes place when a light beam arrives from the light source at one of side surfaces of each ridge, and surface penetration takes place when the reflected light beam arrives at the other side surface of the ridge under consideration. Thus, the conical surface acts both as a reflective surface and as a refractive surface for achieving a desired light distribution pattern.

A process for fabricating an optical device includes injecting (301) optical silicone into a mold cavity formed by two or more mutually matching mold-elements, curing (302) the optical silicone contained by the mold cavity, and separating (303) the mold-elements from the optical device constituted by the optical silicone. The reversible elasticity of the optical silicone after the curing phase is utilized in the process so that at least one of the mold-elements has counterdraft which causes a reversible deformation in the optical device when the mold-element is separated from the optical device. As the counterdraft is allowable, the shape of the optical device as well as the dividing joints between the mold-elements can be designed more freely. For example, walls of the mold cavity corresponding to optically active surfaces of the optical device can be arranged to be free from dividing joints between the mold-elements.

This invention relates to a die tool, a device and a method for producing, in particular embossing, a monolithic lens wafer that has a large number of microlenses.

The present disclosure provides an elastic electronic circuit adapted to provide three dimensional elasticity while conforming to the curved or angled structures of a swellable medical device, such as a hydrogel or silicone hydrogel contact lens. The elastic electronic circuit can include a first pattern for flexibility in a first dimension, a second pattern for flexibility in a second dimension, and a third pattern for flexibility in a third dimension. Alternatively, the elastic circuit can include a first pattern for flexibility in a first dimension and a second pattern for flexibility in a second dimension. The resulting three-dimensional elasticity enables the use of electronic circuits on soft contact lenses, where manufacture and use will cause the lenses and circuits to swell and shrink. Furthermore, the electronic circuit will not distort the vision correction of the contact lens or otherwise cause discomfort or other negative side effects.

A curved lens protector can include a tempered glass body having a self-supporting x-y axis curve with a concave inner surface and a convex outer surface opposite the inner surface. The tempered glass body can have an outer boundary of a predetermined shape to substantially match and fit with respect to an inner boundary of a lens holder portion of a predetermined lens frame. The tempered glass body can be configured for attachment to a predetermined curved lens without the use of an adhesive.

The invention relates to a method for producing embedded hydrogel contact lenses each having a magnetized insert that comprises magnetic particles and is centrally embedded in the bulk hydrogel material of the embedded hydrogel contact lens. During molding, a magnetized insert can be centered and held in position in a lens mold by using a magnet placed below the lens mold. The invention also relates to an embedded hydrogel contact lens produced from a method of the invention.