The Process Behind Creating Contact Lenses

The manufacturing process of contact lenses might be more intricate than you think. Whether you are wearing a pair daily or have just been given a prescription for the first time, knowing how your lenses are made can help you appreciate the technology that goes into your clear vision. You might be surprised to learn how different types of lenses require different manufacturing methods. 

Different Types of Contact Lenses

Contact lenses fall into three types:

• Soft lenses. Thin and flexible, they’re made from a gel-like, water-containing plastic.
• RGP lenses. These are durable and can resist deposit buildup, providing clearer and crisp vision.
• Hybrid lenses. They combine the best of both worlds, offering the exceptional clarity and durability found in RGP lenses, along with the comfort and flexibility of soft lenses. 

The Manufacturing Process

Soft lenses, being flexible and thin, are made using spin-casting. A reactive liquid mixture is poured into a mold, which is spun at high speed, shaping the lenses through centrifugal force. Ultraviolet light cures or hardens the mixture to form the final product.

RPG lenses, on the other hand, are made using a method called lathe cutting. In this process, a plastic button is cut into a rough lens shape using a computer-controlled lathe machine. The lens is then polished to achieve the desired shape and smoothness.

The manufacturing process for hybrid lenses is more complex. It involves the fusion of two different materials. The rigid center is lathe-cut, similar to the process for RGP lenses. A soft peripheral skirt is injected around the rigid center via injection molding and cooled to solidify. For a smooth finish, the lens undergoes rigorous polishing. 

Quality Assurance in Contact Lens Manufacture

Ensuring the quality of contact lenses is a critical step in the manufacturing process. Each batch undergoes rigorous testing before distribution. This includes checking for defects in the lens shape, clarity and coating.

The lenses undergo tests for comfort and fit, as well as durability. These quality control measures ensure that every lens meets the high standards set by the industry and provides the best vision correction possible for the wearer. To further ensure safety, the lenses are sterilized and packaged in a controlled environment to prevent contamination.

Prioritize Your Eye Health

For your contact lens prescription needs, turn to the experienced optometrists at Northern Virginia Doctors of Optometry! To schedule a consultation, give us a call at any of these phone numbers: (703) 660-9494 (Alexandria), (703) 413-1400 (Crystal City), (703) 522-7676 (Clarendon), (703) 573-1200 (Falls Church), or (703) 467-9080 (Reston). You may also visit our contact page to book an appointment.