Method for making embedded hydrogel contact lenses

A method for producing embedded hydrogel contact lenses, comprising the steps of:

• (1) obtaining a lens mold, wherein the lens mold comprises a female lens mold half having a first molding surface and a male lens mold half having a second molding surface, wherein the first molding surface defines the anterior surface of an embedded hydrogel contact lens, wherein the second molding surface defines the posterior surface of the embedded hydrogel contact lens, wherein the female and male lens mold halves are configured to receive each other such that a mold cavity is formed between the first and second molding surfaces when the mold is closed;
• (2) obtaining an insert which is made of a polymeric material and comprises a front surface, an opposite back surface, a central axis, and a diameter up to about 13.0 mm, wherein the insert comprises alignment features on the front surface for centrally aligning the insert on the molding surface of the female lens mold half with respect to the central axis of the female lens mold half, wherein the alignment features protrude from the front surface, have an identical maximum height and are rotationally symmetric with respect to the central axis of the insert, wherein the alignment features have identical shapes each having a curvature that is at least 2 folds of the curvature of the molding surface at contacting point of each alignment feature with the first molding surface;
• (3) placing the insert in a female lens mold half in a way to ensure the insert be centered in the female lens mold half on the first molding surface;
• (4) introducing a lens-forming composition in the female lens mold half in an amount sufficient to immerse the insert in the female lens mold half;
• (5) placing the male lens mold half on top of the female lens mold half and closing the male and female lens mold halves to form a molding assembly comprising the lens-forming composition and the insert immersed therein in the molding assembly;
• (6) curing the lens-forming composition in the molding assembly to form an embedded hydrogel lens precursor that comprise a bulk hydrogel material formed from the lens-forming composition and the insert embedded in the bulk hydrogel material and centered in the embedded hydrogel lens precursor;
• (7) separating the lens mold obtained in step (6) into the male and female lens mold halves, with the embedded hydrogel lens precursor adhered on a lens-adhered lens mold half which is one of the male and female lens mold halves;
• (8) removing the embedded hydrogel lens precursor from the lens-adhered lens mold half;
• and
• (9) subjecting the embedded hydrogel lens precursor to post-molding processes including a hydration process and one or more other processes selected from the group consisting of extraction, surface treatment, packaging, sterilization, and combinations thereof to form the embedded hydrogel contact lens.