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Influence of Mold Design and Molding Conditions on the Optical Properties of Contact Lenses.

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Evaluation Method for Resin Mold Using Reflective Wavefront Sensor.

Kazumasa Tatsumi1,2, Kentaro Saeki1, Shin Kubota1

  • 1SEED Co., Ltd., 2-40-2 Hongo, Bunkyo-ku, Tokyo 113-8402, Japan.

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Summary
This summary is machine-generated.

A new optical evaluation method precisely measures resin molds for contact lens (CL) manufacturing. This technique detects subtle shape variations, improving CL quality and production processes.

Keywords:
OCTcontact lensesinjection moldingresin moldwavefront sensor

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Area of Science:

  • Optical Engineering
  • Materials Science
  • Manufacturing Technology

Background:

  • Contact lens (CL) manufacturing utilizes double-sided molding with resin molds.
  • Thermal deformation during polymerization can negatively impact mold shape and final lens optical properties.

Purpose of the Study:

  • To propose and validate a high-precision optical evaluation method for resin molds used in CL manufacturing.
  • To assess the impact of mold design and thermal treatment on optical characteristics.

Main Methods:

  • Utilized a reflective wavefront sensor for high-accuracy optical measurement (≈1/100λ).
  • Employed optical coherence tomography (OCT) to measure mold thickness asymmetry.
  • Evaluated five mold designs with varying radii of curvature (6.500–8.500 mm).

Main Results:

  • Wavefront sensor demonstrated high reproducibility (≈1/200λ) and measured mold values of 0.012–0.015 μm.
  • Zernike coefficients, particularly astigmatism (Z04) and coma (Z07), varied with mold design and thermal conditions.
  • A strong correlation was found between Z07 and mold thickness asymmetry; a 2.3x increase in thickness difference led to a 1.9x increase in Z07.

Conclusions:

  • The proposed method enables precise detection of subtle shape variations and aberrations in resin molds.
  • This technique provides valuable feedback for optimizing molding conditions and enhancing contact lens quality.
  • The method is applicable to the quality evaluation of other optical components.