How Lenses Are Made
Lens Casting
Before you process a lens for a prescription, you need to start with a lens blank. Here’s how we make one from start to finish.
Step 1
PReparing the Mold
When an order comes in, if we don’t already have the lens blank in stock, we manufacture it in-house. The process begins with a front mold and a back mold, which are placed inside a rubber gasket. This gasket, along with a giant rubber band, hold the molds securely in place.
Step 2
Pouring the monomer
Next, we pour the monomer material between the molds. This mixture is made of two parts:
- The ophthalmic material, a clear syrupy liquid
- The initiator, which triggers a controlled chemical reaction
When combined, these components generate heat and begin forming the solid lens material.
Step 3
Controlled Curing
The filled molds are placed into an oven for a carefully monitored 22-hour curing process. This slow and even heating ensures stability - preventing cracks and flaws that could compromise the final product. By controlling the heat over time, we create a strong, reliable blank that can later be shaped into prescription lenses.
Step 4
Quality Check
After curing, the lenses are removed from the molds in a process called de-blocking. Each blank then undergoes a rigorous quality check. We inspect the surface for scratches, bubbles or any imperfections that could affect clarity. Only lenses that pass this inspection move forward.
Next sTeps
Ready For the Lab
Once approved, the finished lens blanks are labeled, boxed and shipped to our lab where they’ll be surfaced and shaped into custom prescription lenses.