Rotlex guarantees precision from the mold through a six-step quality control process. This process offers micron-level accuracy. It uses dedicated tools and integrates smoothly into the production line for better efficiency.
Stage 1: Metal Insert Inspection
Stage 2: Plastic Mold Surface Measurement
Stage 3: Mold Combination & Air-Gap Analysis
Stage 4: Sag & Base Curve in Saline
Stage 5: Optical Parameter Verification
Stage 6: Automatic Cosmetic Defect Inspection
Stage 1: Metal Insert Inspection
Verify that metal cores (inserts) are free of surface defects before overmolding.
Measured Parameters:
- Radius of curvature (ROC)
- Cylinder
- Axis
- Sagittal height (SAG)
- Tool offset
- Surface quality
- Aspheric
BRASS 2000 –Captures the entire optical profile in one non-contact pass and assists in lathe setup.
BRASS 3K- Batch-inspection mode for rapid submicron surface error detection.
Why It Matters?
Insert inspection is important for making perfect plastic molds. Any defect here affects every mold you produce. This helps you save on factory costs before moving to the next stage.
Stage 2: Plastic Mold Surface Measurement
Scan the raw plastic mold’s internal and external surfaces immediately after injection.
Measured Parameters:
- Radius of curvature (ROC)
- Cylinder
- Axis
- Sagittal height (SAG)
- Tool offset
AMI- Measures up to 72 molds or inserts in one click, providing detailed surface-quality data.
ASIS- Robot-integrable automated surface inspection system for inline deployment.
Why It Matters?
Ensures your mold cavity matches design intent, preventing flash, warpage, and dimensional drift in production.
Stage 3: Mold Combination & Air-Gap Analysis
Verify alignment and air-gap uniformity between the two mold halves.
Measured Parameters:
- Group refractive index (RGI)
- Center thickness
- Sagittal height (SAG)
MCT-3000- Non-contact laser interferometer measuring thickness and refractive properties with 1 µm resolution even in automated lines.
Why It Matters?
Uneven air gaps lead to inconsistent filling, weld lines, and dimensional variation. Early detection keeps cycle times tight and rejects low.
Stage 4: Sagittal Height, Base Curve & Air Gap Measurement
The mold assembly, comprised of a male (front) and female (back) half, is filled with pre-polymer liquid that cures into the final lens. Before curing, we measure the liquid meniscus and the spacing (air gap) between the mold halves under hydrated conditions.
Measured Parameters:
- Air Gap
- Sagittal Height (SAG)
- Base Curve
MCT-3000 –A non-contact laser profilometer measures the curve of the liquid meniscus. It also measures the air-gap thickness with very high precision, even when the mold is completely wet.
Why This Matters?
By measuring the air gap, hydrated sagittal height, and base curve, you confirm that the mold shape will create the right lens thickness. This ensures a good fit and optical performance after curing. It helps maintain comfort and vision quality when worn.
Stage 5: Optical Parameter Verification
Confirm the mold’s optical prescription capabilities before mass production.
Measured Parameters:
- Sphere power
- Cylinder & Axis
- Prism
- Wavefront aberrations
- Addition
- Diameter
- Surface quality
Contest 2 –Advanced lens-mapping platform delivering rapid, precise measurements, including wavefront analyses.
Contest MP- Mass-production mode for diverse designs, wet/dry/hydrated conditions.
Why It Matters?
Guarantees that every mold can produce lenses meeting tight refractive specifications and delivers consistent visual performance.
Stage 6: Automatic Cosmetic Defect Inspection
Detect any exterior imperfections that would impact lens aesthetics.
Inspected Defects:
- Edge chips
- lathe errors
- Lathe marks
- scratches
- Suction-cup marks
- Laser burn-in errors
- Polish marks
- orange peel
V-PRO GS3- This machine-vision system provides high-resolution imaging. It makes automated Go/No-Go decisions based on set defect criteria.
Why It Matters?
A flawless mold surface translates directly into flawless lenses—every cosmetic defect caught here prevents customer complaints downstream.
Rotlex six-step Precision Security Loop combines smart automation, advanced measurement, and smooth production-line integration.
This process ensures unmatched accuracy in mold creation, from metal insert to finished lens
Enhance lens quality and throughput
Contact us for a bespoke consultation and discover the ideal solution for your line.
