Ophthalmic eyewear with lenses cast into a frame and methods of fabrication

Abstract

The present invention is directed to a method of manufacturing spectacle lens eyewear using a block mold, front and back optical inserts, front and back optical insert gaskets, a protractor insert, a closing mechanism and a preformed frame, the method comprising the steps of: selecting a front optical insert from a look up table or computer program product and assembling the insert into the block mold; selecting a front optical insert gasket and assembling the gasket onto the front optical insert; assembling the frame front onto the front optical insert gasket; selecting a back optical insert gasket and assembling the gasket onto the back side of the frame front; selecting a back optical insert from a look up table or computer program product and assembling the insert onto the back optical insert gasket; assembling the protractor insert and adjusting the position of the back optical insert to the axis indicated on a look up table or computer program product; assembling the mold closing mechanism and securing the mold; filling the cavity through a first capillary tube; curing the closed mold to polymerize the lenses; removing the ophthalmic eyewear from the block mold and releasing the front and back optical inserts and insert gaskets; and removing the capillary tube housing and attaching earpieces.