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Production process

Free Form RX laboratory production process

The first installation Auto Taper attaches a protective tape on the outer side of lens blanks prepared for production. During production, it will protect the lens blanks from damages.

In the next stage, blanks with a protective tape travel to the main lens processing line (Modulo line). The line is fully automated and controlled from a control centre where one can monitor and, if necessary, change the status of orders in the line, and subsequent processes. All machines is set out in a circle, and lenses are transferred from one device to the other with an automatic distribution and transportation conveyor system.

 

Equipment and procedures of the automatic lines (Modulo line):

1. The CCU fully automated blocker on each workpiece, in the side covered with a protective tape, places a form on the casting ring through which the alloy is poured. Before that, the automatic hand puts the block piece on the middle of the ring, to help the workpiece travel across all the units of equipment in the automated line. In the case of non-standard lens diameters and shapes block piece can be cast with a CB Bond mechanical blocker. The block piece is used for attaching a lens to the equipment fasteners during the processes.

2. Blocked lenses in the CCS collector are kept for 40 minutes to cool down to room temperature to prevent lens deformation or other defects during generation and production processes. After the required period of time CCS releases orders to the conveyor line one after the other for further production processes.

3. The HSC XT fully automatic lens generator prepares the inner surface of the workpiece with  extra high precision, making three cutting steps, while the final cutting is carried out using a 2 mm natural diamond (with accuracy of 1 μm) to create the diopters specified to the patient's prescriptions.

4. After generating a lens, the order proceeds to the automated polisher CCP where both lenses are simultaneously polished in two polishing steps, using different surface roughness tools, according to specified parameters.

5. The next step is checking the lens quality with the automated device PMD. This equipment allows to check the lens surface quality before deblocking, and without stopping the entire conveyor system and other orders on it. The equipment illuminates the lenses with ultraviolet light, while two extra high-resolution cameras located inside take thousands images of the surface (lens relief scanning). Upon completion of the lens surface measurements, the diopter and the surface smoothness map shows up on the computer screen to demonstrate the lens surface and quality parameters.

6. The CCL automatic CO2 laser marks the geometry points on the lens surface for progressive lens centring during cutting.

 

  • After the production processes in the Modul line, the lenses are unblocked. In DBA device 2, alloy is melted in hot 63 °C deionised water and separated from the holder.
  • The TSA 2 unit is used to remove the protective tape from the outer surface of the lens by spraying high-pressure 80 bar water flow.
  • The next step is quality control, where lensmeter is used to check the finished lens diopters and their surface quality.
  • Lenses are then cleaned with special solvents in USC 200 ultrasonic baths and, without contact with the environment, delivered to high cleanliness premises where their resistance is increased using the DHC 200 device by coating them with hard coatings.
  • Flow Bench high clean and extraction laminars are used for cosmetic quality inspection work.
  • After the hard coating, lenses are placed in UF 260 ovens, where coatings finally cure on the outer surface of the lens.
  • Through the opening in the wall, lenses are transferred to other areas of the hermozone where similar manual work of cosmetic inspection and sorting is carried out in Flow Bench laminars.
  • Sorted by diameters and indices, lenses are placed in the EBC 900 furnace to cover them with anti-reflective surface coatings. The process includes the evaporation of chemicals with anti-reflective properties. After the application of anti-reflective coatings the quality of lens is again checked. After the inspection, lenses are packed for dispatch or for cutting and framing.
  • Then, the lenses are delivered to the final stage – profile shaping, and framing. Precision HSE and HSE BLS (Blockless) cutting devices cut lenses for any type of spectacle frames. This can be a standard full rim, half-frame with a nylon string, or screw-type rimless option. Cut lenses are immediately framed by lab technicians or, can be sended to the costumers without framing. The cutting and framing is followed by the final quality inspection of all lenses and glasses, in accordance with the applicable standard LST EN ISO 14889, checking the lens diopters, cosmetic appearance and framing workmanship quality.