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Surfacing Overview In Pictures

Learn about the process of surfacing lenses, where curves are ground with precision to create the necessary power or prescription. Explore the steps of grinding, fining, and polishing, and discover the tools and equipment used in the process.

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Surfacing Overview In Pictures

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  1. Surfacing Overview In Pictures Also Called: Generating, Grinding The creation of lens power through the grinding of curves DL = D1 + D2

  2. Surfacing Is --- • How a lens is created • Lens begins as a chunk of plastic (or glass) that is finished on the front but is just raw plastic (or glass) on the back • The back side is ground away with great precision with specific curves to match the curve on the front • This creates the necessary power or prescription

  3. The Nominal Lens Formula DL= D1 + D2 • DL = The power of a lens in diopters • D1 = The front curve or power • D2 = The back curve or power • DL = D1 is +8.00 D2 is -7.00 • + 8.00 + -7.00 = +1.00 • DL = +1.00

  4. DL= D1 + D2 • If the front base curve is a convex shape with positive or +8.00 power • And the desired Rx is +1.00 • I will need to grind a concave minus -7.00 curve on the back of the lens

  5. Surfacing Is A 3 Step Process • Grinding (surfacing, generating) • Removes material from back of lens • Fining • Brings backside of lens to almost clear • Polishing • Brings backside of lens to perfect smooth clear finish that you can see through

  6. Job Order FormsIt takes thousands of individual calculations to determine what curves will be ground.

  7. Lens blanks come from the factory finished on the front but just raw plastic on the back

  8. Lens BlanksA lab will stock thousands of them!

  9. Lens Blank StockS/V, Lined, Progressive, Transition, Polarized, Occupational, CR-39, Poly, Glass, Hi-Index…

  10. Preparing Lens BlankFor all sphero-cylinder lenses axis position must be marked before blocking the lens

  11. Protecting Lens BlankPlastic film placed over the front of the lens protects it from heat and scratching

  12. Lens Is “Blocked”Alloy or wax is used to hold the lens blank to the surfacing blockThe block holds the lens in place through entire surfacing process

  13. Lens blank is held to bock with alloy • Block assures proper alignment in grinder • Alloy creates bond with the lens & tape • Alloy is melted and reused

  14. Lens blank attached to block • Note the various openings that hold block in the correct position

  15. Job Ready for SurfacingJob ticket for grinding parameters, lenses attached to blocks

  16. Surfacing Layout ScreenProvides all the information that the generator needs to complete the job • Job number • Base curve • Cross curve • Center thickness • Crib diameter • Pin Bevel • Layout Axis • Prism • Front curve • Back curve • Edge thickness • Diameter • Material • Block • Tool • Aren’t you glad we have computers!

  17. Generator Cutting Wheel and Chuck Chamber • The orange nozzle sprays water on the lens and tool for cooling • The tool seen on the right has diamond blades that will cut away the back of the lens • The lens is seen on the left

  18. Lens Off GeneratorNote Faint Red Axis LineLens back side is now an opaque smooth white with defined curves

  19. Fining • Lens is chucked in machine • Lens is sandwiched between block and a mild abrasive pad • Water or lubricant is sprayed on pad while pad oscillates over a tool that matches the backside curves with near perfect precision

  20. Job TraySurfaced LensesLap Tools With Fining Pads

  21. A lab must stock thousands of tools to match the nearly infinite number of prescription curves

  22. Tools may be for spheres or sphero-cylinder prescriptions

  23. Machine holds lens in place using the block and pushes it against the tool which is covered with an abrasive pad.

  24. FiningPerformed on a “cylinder machine”

  25. Fining process

  26. Lens Ready For Polishing Note how thin the lens is now

  27. Polishing • Uses same technique as fining but uses a soft pad and mild abrasive slurry instead.

  28. Lens After Surface, Fine and PolishReady for de-blocking and finishing

  29. Also See PowerPoint Presentation On Finishing Finishing is the cutting of the surfaced lens to fit a frame

  30. Labs Also • Stock single vision un-cut lenses • Tint lenses • Drill lenses • Assemble complete pairs • Add decorative touches to lenses • Some stock frames • Some apply anti-reflective coatings in house • Labs can be as small as a few hundred square feet or as large as a factory

  31. TAKE A TOUR! Contact your nearest optical lab and ask for a detailed tour. Ask Questions! Spend the day! LEARN!

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