UV LED Curing for Silicone Hydrogel Contact Lenses: Breakthrough in Curing Properties and Cosmetic Characteristics

Ultraviolet light-emitting diode (UV LED) technology offers advantages over conventional UV mercury (UV Hg) lamps, including precise wavelength control, high energy efficiency and rapid curing. While UV LED is widely applied in sectors like dentistry, printing, and electronics, its application in contact lens manufacturing remains relatively low. This study evaluates the feasibility of integrating UV LED technology curing as a replacement for UV Hg lamps to produce silicone hydrogel contact lenses. Many manufacturers utilizing UV Hg systems encounter challenges such as extended curing times and increased cosmetic defect rates. In this study, lenses were formulated using a mixture of hydrophobic macro-monomer, silicone monomer, and hydrophilic monomer. The formulations were cured using both UV LED and UV Hg lamps systems under controlled intensities, and two curing configurations were assessed: single-sided (SC) and double-sided (DC). The UV Hg light intensity was maintained between 1.1 and 3.1 mW/cm², reflecting standard production values, while the UV LED intensity was set at 32 mW/cm² to ensure uniform light distribution in the mold. The findings showed an improved degree of conversion (DOC) for UV LED cured lenses (86-88%) compared to UV Hg (79.5-82.3%), along with increased water content (ranging between 34 and 36.8%) and ion permeability (7.1-8.3 mm²/min). The optical properties of the cured lenses remained consistent across both methods. Notably, UV LED curing reduced cosmetic defects by up to 50% and shortened curing time by 3 to 4 times. These enhancements support UV LED as a superior alternative for contact lens curing, enabling scalable, efficient, and high-quality manufacturing.