Systems and methods for insert placement to fabricate hybrid contact lenses

An insert placement and molding system for fabricating a hybrid contact lens product having a lens insert embedded within a lens body, the lens insert comprising a first material and having a concave back surface and an opposite convex front surface, and the lens body comprising a second material different from the first material, wherein the insert placement and molding system comprises:

• a lens forming mold element which is a female mold half having a circular and concave central mold receptacle and a circumferential flange defining an internal geometry and surrounding the central mold receptacle;
• a mold engagement and support base comprising a body having a planar top and a bottom surface and at least one mold engagement feature configured to engage a lens forming mold element and retain the lens forming mold element in a substantially fixed position relative to the mold engagement and support base;
• an insert placement and positioning device comprising a positioning housing, a suction conduit connected to an external suction source and extending centrally and axially through the positioning housing from top to base, an insert pick-up head mounted to the suction conduit, and a positioning ring coupling the suction conduit with the positioning housing at the top of the positioning housing, wherein the insert pickup head comprises an insert contact face configured for cooperative releasable engagement of the lens insert, at least one suction opening in fluid communication with the suction conduit, and at least one pressure relief channel, wherein the positioning housing comprises at least one positioning feature which comprises an external geometry and outside diameter around its base that is configured for a clearance or interference fit within the internal geometry of the circumferential flange of the lens forming mold element to provide precise locational positioning of the insert pickup head relative to the lens forming mold element both in an axial dimension and in a transverse dimension orthogonal to the axial dimension;
• and
• a centering jig for positioning the lens insert for pickup by the insert placement and positioning device.