How to make contact lenses
The manufacturing process for contact lenses depends on whether the lenses are soft contacts, rigid gas permeable contacts or hybrid lenses.
Lathe cutting. In this process, non-hydrated disks (or "buttons") of soft contact lens material are individually mounted on spinning shafts and are shaped with computer-controlled precision cutting tools. After the front and back surfaces are shaped with the cutting tool, the lens is then removed from the lathe and hydrated to soften it. The finished lenses then undergo quality assurance testing.
Though the lathe cutting process has more steps and is more time-consuming than an injection molding process, over the years the process has become more automated. With computers and industrial robotics, it now takes only a few minutes to create a lathe-cut soft contact lens.
Injection molding. In this process, the soft contact lens material is heated to a molten state and is then injected into computer-designed molds under pressure. The lenses are then quickly cooled and removed from the molds. The edges of the lenses are polished smooth, and the lenses are hydrated to soften them prior to undergoing quality assurance testing.
Most disposable contact lenses are made with an injection molding process, as this method is faster and less expensive than lathe cutting processes.
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