A casting method involves providing a precursor to a mold that includes a deformable surface overlying a chamber, shaping the deformable surface according to a surface profile by adjusting a fluid pressure within the chamber and driving one or more actuators that are configured to distort the deformable surface, and solidifying the precursor while the deformable surface is shaped according to the surface profile to form an optical element.

Disclosed are in-line apparatuses, systems and methods for measuring a physical characteristic of a constant supply of an ophthalmic device, the apparatuses including: an interferometer; an automatic alignment system that positions the interferometer or ophthalmic device; and a central processing unit in communication with the automatic alignment system and receiving measurements from the interferometer. The in-line apparatus measures the desired physical dimensions of the ophthalmic device in real time. In-line systems, apparatuses and methods for measuring a physical characteristic of an ophthalmic device can include: a camera imaging an actual position of a feature of the ophthalmic device; a vibration resistant interferometer projecting a surface measurement beam having a wavelength that transmits through a beam splitter onto the ophthalmic device; and an automatic alignment system positioning the interferometer and the camera.

A method includes the steps of measuring a surface profile of a first component, determining a profile of a second component, the profile of the second component being configured to correspond to the surface profile of the first component, and manufacturing the second component utilizing additive technology in accordance with the determined profile.

A system for manufacturing ophthalmic devices, in particular contact lenses or intraocular lenses, includes at least one injection molding machine for manufacturing a cup bottom part and cup top part to form a cast mold, a cooling station, an injection assembly arranged for injecting an amount of monomeric material into the cup bottom part, a curing assembly, a first optical inspection assembly for determining at least one first optical cup part parameter, a second optical inspection assembly for determining at least one optical combination parameter of the combination of the cured monomeric material formed into a lens and the cup part that bears the lens, and an electronic control provided with a calculation module for determining at least one optical lens parameter of the lens on the basis of the cup part parameter and the combination parameter. Possibly, production parameters can be adjusted on the basis of trend changes of the lens parameters of produced lenses.