Lab Equipment in the 21st Century

New surface generators and in-office edgers will improve the quality and accuracy of ophthalmic lenses.

As you've undoubtedly noticed, our industry is changing. We see technological advances in almost all areas of optometric practice. For example, new diagnostic instruments seem to pop up at every turn and new therapeutic agents treat diseases while causing fewer side effects. But an area of our industry that's on the verge of unnoticed historical change is the wholesale optical laboratory.

Let's see what the future holds for wholesale labs and in-office operations.

In your office

Manufacturers are developing new technology in the finishing area. The latest edgers are capable of not only loading themselves with the aid of robotics, but can edge lenses to size and shape, apply pin bevels, and roll and polish the edges at a single stop. If the machine is designed appropriately, labs can also drill holes automatically for drill-mounted prescriptions. All of this automation with one piece of equipment! This technology can be found in some of the latest edging equipment that's available for in-office labs.

The way we send job orders to the laboratory is also changing. We now have the technology to allow the electronic transfer of order data and the lens (frame) shape information (derived from frame tracers) directly from your office to your lab host computer. This eliminates order data entry errors, gets your work in progress much faster and provides more precise information so that the lab equipment will be set more accurately.Our lab partners have given us years of reliable service and quality products. While they have provided continual changes in technology as well, they're now preparing for some major advances. First and foremost is the development of "free-form" technology in the production of prescription ophthalmic lenses. To understand this change, we need to look at how labs have produced lenses historically.

A glimpse of the past

The initial step in producing prescription ophthalmic lenses utilizes partially prepared lenses called semi-finished blanks. The laboratory purchases these blanks from lens manufacturers in a variety of base curves formed on the front surface. In addition, if the blanks are multifocal (either in segment form or in progressive form), then this is formed on the front surface as well. The lab stocks the blanks in a variety of materials and refractive indices.

When the lab receives your order, it chooses a semi-finished blank based on the prescription information. The generator uses the calculations it receives to set the machine parameters, enabling it to remove back surface material from the lens to create the spherical and astigmatic power needed to fulfill the prescription. When the lab completes this process, the lens has a thickness and powers that are accurate, but in a roughened state.

The next step has been to use a tool called a lap to "fine" the lens. These laps are customarily made out of aluminum and have a rounded front surface. Labs stock them in progressive steps of different curvatures. The optician applies a rough granular pad to the curved surface of the lap so that it can be used to further remove material while polishing the generated surface of the lens. As mentioned, the lab produces laps in progressive steps of curvature, therefore we're getting approximately close to the desired curve, but usually not exact. Finally, the tech takes the lens to a polishing machine to smooth the surface.