A modular production line for the production of contact lenses comprises at least three separate modules: a manufacturing module (MM), an inspection module (IM), and a packaging module (PP).

The modular production line further comprises fixedly arranged transfer interfaces between the individual modules (MM, IM, PP) for transferring the lenses from a preceding module to a subsequent module. The manufacturing module (MM) comprises a plurality of manufacturing stations (300, 301, 302, 310, 320, 321, 322, 330, 331, 340, 341, 342, 350, 351, 352) which are grouped to form a plurality of individual manufacturing units (30; 31; 32; 33; 34; 35) arranged in a closed loop. Reusable male and female molds (212, 112) are transported through the manufacturing stations of the manufacturing units, and each manufacturing unit (30; 31; 32; 33; 34; 35) comprises a plurality of the manufacturing stations (300, 301, 302, 310, 320, 321, 322, 330, 331, 340, 341, 342, 350, 351, 352). A plurality of transfer robots (36) is provided, each transfer robot (36) of the plurality of transfer robots (36) being arranged at a location between two manufacturing units (30; 31; 32; 33; 34; 35) to transfer the reusable molds from one manufacturing unit to the other manufacturing unit.

A method of removing a liquid from a container (1) for accommodating an ophthalmic contact lens, in particular a soft contact lens, during transporting the container (1) from a liquid bath (13) to a subsequent processing station (14), the method including the steps of: transporting the container (1) from the liquid bath to the subsequent processing station, generating suction (20), and applying the suction (20) to a bottom (11) of the container (1) during the step of transporting the container (1) from the liquid bath to the subsequent processing station, thereby removing the liquid from the container (1).

A diagnostic station for inspecting an article transport vehicle movable along a guideway has a diagnostic module associated with the guideway and configured to receive the article transport vehicle when the article transport vehicle is in an inspection position along the guideway. The diagnostic module has at least one of the following: a grip testing substation having at least one force sensor configured for measuring a force exerted by a closure mechanism of the article transport vehicle in a closed position, a pressure testing substation in communication with a source of pressurized air and configured for pressurizing and depressurizing the closure mechanism, and an optical inspection substation having at least one camera configured for capturing image data of the article transport vehicle.

A method for transporting a packaging shell (1) of an ophthalmic lens package comprises the steps of at a start location providing a packaging shell (1) comprising a depression (10), and a flange (11) completely surrounding the depression (10), providing a suction cup (2) having an opening (21) at a distal end thereof, which is completely surrounded by a rim (22) sized and shaped to engage the flange (11) in an engagement area completely enclosing the depression (10), positioning the suction cup (2) and the packaging shell (1) such that the rim (22) and the engagement area of the flange (11) face each other, moving the suction cup (2) and the packaging shell (1) towards each other, applying suction through the opening (21) of the suction cup (2), moving the suction cup (2) with the packaging shell (1) adhered thereto to the destination location, at the destination location releasing the suction, wherein a flexible sealing gasket (3) is arranged at the rim (22) to sealingly engage the flange (11) in the engagement area.

A method for automated in-line determination of the center thickness of an ophthalmic lens including providing an inspection cuvette (2) having an optically transparent bottom (21) and a concave inner surface (210) and containing the lens immersed in a liquid, providing an interferometer having a light source and a focusing probe (30) focusing light coming from the light source to a set position (310) of the lens. Focusing probe (30) also directs light reflected at the boundary between the back surface of the lens and the liquid as well as light reflected at the boundary between the front surface of the lens and the liquid or at the boundary between the front surface of the lens and the concave inner surface (210) to a detector of the interferometer. The center thickness of the lens is determined using the light reflected at the respective boundary at the back surface and at the front surface of the lens.

Apparatus and methods are described for manufacturing contact lenses by forming a contact lens mold half, and removing the mold half. The mold half can then be combined with a complementary mold half and used to cast-mold a contact lens. The apparatus includes first and second plates each carrying tool halves. The plates reciprocate between an open, spaced apart configuration, and a closed configuration in which they hold complementary tool halves in contact with one another. When the plates are opened after forming a mold half, a gripper plate removes the mold half from the first plate or the second plate.

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.

A method of manufacturing an ophthalmic lens using a first mold portion and a puck assembly. The puck assembly comprises a carrier puck. The puck assembly supports at least one of the first mold portion and the lens during at least two of the following ophthalmic lens manufacturing steps: assembling the first mold portion and a second mold portion into a mold assembly including a lens-defining cavity containing a lens precursor material; curing the lens precursor material in the mold assembly to form a lens; separating the mold assembly such that the lens remains attached to the first mold portion; detaching the lens from the first mold portion; extracting unwanted material from the lens; hydrating the lens; inspecting the lens, and packaging the lens.

A toric contact lens (1) having a front surface and a rear surface, one of said front and rear surfaces includes a toric optical zone and a lens edge surrounding the contact lens (1). The contact lens further has a ballast axis (3) and includes at least one ballast mark (41, 42, 43) identifying the position of the ballast axis (3). Each ballast mark (41, 42, 43) includes a one-dimensional dot pattern (5) having a lens identification code and being arranged to extend radially towards the lens edge at an angular position relative to the position of the ballast axis (3). The angular position of the one-dimensional dot pattern identifies the position of the ballast axis.

An automated production line for the production of ophthalmic lenses comprises: a production line front end (1) comprising: a first injection-molding machine (10) and a second injection-molding machine (12) a casting module (14) comprising a filling station (144) and a capping station (145); a stacking module (15) and a curing module (16); a destacking module (17) and a demolding and delensing module a production line back end (2) comprising: a scalable treatment module (20) comprising a number of liquid baths for a liquid bath treatment of the cured lenses (CL) carried by the treatment carrier tray (200) to obtain the ophthalmic lenses, wherein the number of liquid baths are reduced or increased pending on the number of ophthalmic lenses concurrently produced by the production lines.