A method of forming a mold insert used to produce an intraocular lens (IOL) mold is disclosed herein. The method includes providing stock material and cutting the stock material, which includes multiple cutting steps. The cutting steps are performed on transitional regions of supporting portions of the mold insert. Peripheral surfaces of the mold insert have varying roughness values, and supporting portions of the mold insert have a greater roughness than the optical portion of the mold insert. An IOL is also disclosed herein that is formed using an IOL mold that is injection molded using the mold insert. A method of forming the IOL is also disclosed herein.

A method of measuring an axis angle of a toric contact lens including a posterior toric central zone having a cylindrical axis, and an anterior lens surface forming a ballast that has an axis of orientation offset from the cylindrical axis at a selected rotational angle is disclosed. The method involves (a) providing anterior and posterior mold sections including respective anterior and posterior mold cavity defining surfaces, wherein the posterior mold cavity defining surface includes a toric central zone and the anterior mold cavity defining surface is shaped to provide the ballast, the mold sections being alignable at multiple rotational positions; (b) providing a detectable feature on each of the anterior and posterior mold sections at a predetermined angular location with respect to the tonic and ballast axes thereof, respectively; (c) rotating the detectable feature of the posterior mold section relative to the detectable feature of the anterior mold section, wherein the detectable feature of the anterior mold section is a zero reference; and (d) measuring the axis angle between the detectable feature of the posterior mold section relative to the detectable feature of the anterior mold section after rotational displacement of the mold sections during toric contact lens formation.

A method of providing a male mold half (1) for molding a toric contact lens at a predetermined target rotational orientation is disclosed. The male mold half comprises a front face (10) having a toric convex lens-forming surface (100) and a rear face (11) The method comprises the steps of: providing the male mold half (1) at a predetermined rotational orientation (PROM), picking the male mold half (1) up with a gripper (5) having a central axis (55), rotating the gripper (5) with the male mold half (1) about the central axis (55) of the gripper (5) by a predetermined rotational angle (α) towards the predetermined target rotational orientation (TROM), and releasing the rotated male mold half (1) from the gripper (5).

Prior to picking the male mold half (1) up, the method comprises centering the gripper (5) and the male mold half (1) relative to each other such that the central axis (55) of the gripper and a central axis (113) of the male mold (1) half coincide.

A method of manufacturing of an astigmatic contact lens having a toric portion and a thickness differential feature to provide lens orientation on eye portion such that said thickness differential causes the toric portion of the contact lens to properly orient in the eye of the wearer. The toric lenses are manufactured by an effective process control method for cylinder power in toric lens production by determining an amount of a mold cylinder compensation which is caused by processes in a toric lens manufacturing system including tool making, injection molding, casting and curing, wherein the mold cylinder is defined as the difference in measured radius of curvature at two orthogonal directions. A control metric is established by using the amount of a mold cylinder compensation and tolerance range and reject mold out of the control limits and improve the production yield for toric lens manufacturing.

Exemplary embodiments of the present disclosure provide a method and apparatus for forming an ophthalmic lens. An exemplary method includes providing a plurality of posterior tools each having a posterior optic defining surface and a plurality of anterior tools each having an anterior optic defining surface, wherein each one of the plurality of posterior tools has a different central posterior optic defining surface including a unique conic section. The method further includes selecting one of the plurality of posterior tools and one of the plurality of anterior tools based on a criteria, and forming a posterior mold by the selected one of the plurality of posterior tools and an anterior mold by the selected one of the plurality of anterior tools, the posterior mold and the anterior mold operable to form an ophthalmic lens having the criteria.

In a toric lens comprising a toric surface having a fine uneven structure, the fine uneven structure includes a plurality of holes, the plurality of holes have a hole depth H and a surface opening diameter φt which satisfy an expression of 0.3≤H/φt≤0.6, and (a) the plurality of holes have a hole structure having a cylindrical shape on a bottom surface side and a circular truncated cone shape having an opening diameter increasing toward a surface side, or (b) an angle θ formed between an opening portion and the surface of the plurality of holes satisfies 78°≤θ≤85°.

A mold unit (22) for molding ophthalmic lenses comprises: an adapter piece (220) comprising an opening (2200) extending around a longitudinal axis (2201); a sleeve (221) fixedly connected to the adapter piece (220) and extending through the opening (2200) of the adapter piece (220); a lens mold (222) rigidly mounted to the sleeve (221); an adjustment ring (224) firmly attached to the sleeve (221) to circumferentially surround a portion of the sleeve (221).

The adjustment ring (224) comprises a flat circular outer engagement surface (2244), and the adapter piece (220) comprises at least one clamping block (2211) having a flat inner clamping surface (2214). The flat inner clamping surface (2214) frictionally clamps the flat circular outer engagement surface (2244) to prevent inadvertent rotation of the sleeve (221) relative to the adapter piece (220) but to allow rotation of the sleeve (221) relative to the adapter piece (220) upon the application of a torque higher than a predetermined threshold torque.

A production line (PL) for the production of ophthalmic lenses (7) comprises a manufacturing module (MM), an inspection module (IM), and a packaging module (PP) in which the lenses identified by the inspection module (IM) as being acceptable are packed into primary packages. 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). At least one of these manufacturing stations (310; 320, 321, 322, 330, 331) is configured to apply a lens identification code (70, 71, 72) to the respective lens. The lens identification code (70, 71, 72) includes information indicative of the type of the respective lens. Either the inspection module (IM) or the packaging module (PP) includes a lens detection station (502, 604) configured to read the lens identification code (70, 71, 72) applied to the respective lens and to detect the type of the lens from the lens identification code (70, 71, 72) read from the respective lens in order to determine whether the type of lens detected actually is the type of lens which is expected to be detected by the lens detection station (502, 604) at that time.

A production line (PL) for the production of ophthalmic lenses (7) comprises a manufacturing module (MM), an inspection module (IM), and a packaging module (PP) in which the lenses identified by the inspection module (IM) as being acceptable are packed into primary packages. 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). At least one of these manufacturing stations (310; 320, 321, 322, 330, 331) is configured to apply a lens identification code (70, 71, 72) to the respective lens. The lens identification code (70, 71, 72) includes information indicative of the type of the respective lens. Either the inspection module (IM) or the packaging module (PP) includes a lens detection station (502, 604) configured to read the lens identification code (70, 71, 72) applied to the respective lens and to detect the type of the lens from the lens identification code (70, 71, 72) read from the respective lens in order to determine whether the type of lens detected actually is the type of lens which is expected to be detected by the lens detection station (502, 604) at that time.

A production line (PL) for the production of ophthalmic lenses (7) comprises

a manufacturing module (MM),

an inspection module (IM), and

a packaging module (PP) in which the lenses identified by the inspection module (IM) as being acceptable are packed into primary packages.

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). At least one of these manufacturing stations (310; 320, 321, 322, 330, 331) is configured to apply a lens identification code (70, 71, 72) to the respective lens. The lens identification code (70, 71, 72) includes information indicative of the type of the respective lens.

Either the inspection module (IM) or the packaging module (PP) includes a lens detection station (502, 604) configured to read the lens identification code (70, 71, 72) applied to the respective lens and to detect the type of the lens from the lens identification code (70, 71, 72) read from the respective lens in order to determine whether the type of lens detected actually is the type of lens which is expected to be detected by the lens detection station (502, 604) at that time.