The present invention general related to a method and a reusable mold for making a contact lens, comprising a first mold half having a first mold surface in contact with a silicone containing lens forming composition and a second mold half having a second mold surface in contact with the lens forming composition. The first mold half and the second mold half are configured to receive each other such that a cavity is formed between the first mold surface and the second mold surface. The cavity defines the shape of a contact lens to be molded. The lens forming composition is polymerizable and/or crosslinkable by actinic radiation. The reusable mold has at least one of the mold halves is made from chalcogenide glasses, Zinc Selenide or Zinc Sulfide.

Provided herein are systems and methods for additive manufacture of a customized ocular contact lens for a subject in a fast and convenient manner. In various aspects disclosed herein, methods disclosed herein provide for the imaging of the outer surface of a subject's cornea, designing a customized ocular contact lens based on the data from the imaging of the cornea, including determining anterior and posterior surfaces of the ocular contact lens, manufacturing the ocular contact lens using additive manufacturing, verifying the fit of the customized ocular contact lens on the subject's cornea, and verifying the optical power of the customized ocular contact lens. These features allow for the fast and convenient production of an ocular contact lens customized to a subject's cornea and manufactured to a specified optical power.

A contact lens package may include a first package layer, a second package layer, a lens receiving area defined between the first and second package layers, a first seal portion between the first and second package layers extending around a first portion of the lens receiving area, a second seal portion between the first and second package layers extending around a second portion of the lens receiving area, and the second seal portion having different sealing properties than the first seal portion. The second seal portion together with the first seal portion complete a seal around the lens receiving area. The first seal portion defines an unsealed gap at a location around the lens receiving area, and the second seal portion closes the gap. The gap allows a flow of fluids after a formation of the first seal.

A contact lens constructed to limit the water transmissibility of at least one area of the lens while maintaining at least a minimum oxygen transmissibility. The water transmissibility maximum and oxygen permeability minimum are achieved by a predetermined lens thickness of a single lens material or by the use of two or more material layers.

A method for making a colorant film providing eye care includes following steps of providing a plurality of microcapsules containing hydrogen peroxide aqueous solution; mixing a hydrophilic monomer, a cross-linking agent, and an initiator to form a mixture; mixing the microcapsules, the mixture, a pigment, and a solvent to form a colorant material; printing the colorant material into a mold; and heating or irradiating the colorant material in the mold to copolymerize the hydrophilic monomer, the initiator, and the cross-linking agent. A colorant film, and the manufacture of an ophthalmic lens are also provided.

Designs, strategies and methods for forming biocompatible batteries with plated cathode chemistries are described. In some examples, an electrolytic manganese dioxide layer may be plated upon a cathode collector before assembly into a micro-battery. In some examples, the biocompatible battery with electrodeposited cathode may be used in a biomedical device. In some further examples, the biocompatible battery with electrodeposited cathode may be used in a contact lens.

Methods and apparatus to form biocompatible energization elements are described. In some examples, the methods and apparatus to form the biocompatible energization elements involve forming cavities composing active cathode chemistry. The active elements of the cathode and anode are sealed with a biocompatible material. In some examples, a field of use for the methods and apparatus may include any biocompatible device or product that requires energization elements.

Apparatus and methods for manufacturing ophthalmic lenses by bringing together a pair of mold halves to form a closed mold assembly, are described. The method includes measuring a force applied to bring the mold halves together. The apparatus includes at least one force sensor in operative communication with a single pair of mold halves, and a controller for controlling a velocity of movement of a mold half and for determining when a measured force or average measured force is greater than or equal to a predetermined threshold force.

Methods and apparatus for exchanging tools and/or tool assemblies used to form different types of molds for in injection-molding machines, are described. The exchange of tools and/or tool assemblies is made using a robot. Contact lens mold halves and assemblies for molding contact lenses of different powers or types can be made with a single injection-molding apparatus.

Methods, devices and systems that allow three-dimensional printing of material with high resolution are described. One example system includes a two-photon polymerization (TPP) subsystem including a first light source coupled to an optical fiber positioned to deliver a first laser light to a scanning optical device, and an optical projection subsystem comprising a second light source configured to provide a second light to a digital projection device. A dichroic mirror is positioned to receive light corresponding to the first and the second light source, and an objective lens positioned to provide illumination to a target material for 3D printing. The dichroic mirror is configured to allow light from one of the light sources to pass therethrough to the objective lens, and to allow light corresponding to the other light source to be reflected towards the objective lens to enable simultaneous illumination of the target material.