System and method to manufacture a contact lens with an embedded element

A system for automated production of a hybrid lens product comprising a lens insert embedded within a lens body, the system comprising:

• a mold carrier-conveyor subassembly which comprises a first carrier platen, a second carrier platen, and a third carrier platen, wherein the first platen comprises a first generally circular disc having a plurality of first receiver openings each configured to hold one female lens mold half and a plurality of first position-indicating openings arranged in an evenly-spaced, alternating pattern, wherein the second platen comprises a second generally circular disc having a plurality of second receiver openings each configured to hold one previously formed lens insert element and a plurality of second position-indicating openings arranged in an evenly-spaced, alternating pattern, wherein the third platen comprises a third generally circular disc having a plurality of third receiver openings each configured to hold one male lens mold half that is configured for cooperative engagement with one female lens mold half and a plurality of third position-indicating openings arranged in an evenly-spaced, alternating pattern, wherein each of the first, second and third carrier platens comprises one rotary stage system and is rotationally mounted adjacent or near at least one of the first, second and third carrier platens to a base so as to receive empty female lens mold halves, to move the empty female lens mold halves sequentially through an active lens forming position, and to discharge completed lens mold assemblies and/or completed lens products after lens molding;
• a three-dimensional pick-and-place subassembly which comprises a platform, an X-axis linear actuator, a Y-axis linear actuator, a Z-axis linear actuator, and a vacuum pickup arm, wherein the vacuum pickup arm comprises a carrier plate rotationally mounted via a motorized rotary actuator stage to the Z-axis linear actuator, a first vacuum pickup head end effector mounted to the carrier plate for picking up and positioning the lens insert elements from the second carrier platen and positioning the lens insert elements in the female lens mold halves in the first carrier platen, a second vacuum head end effector mounted to the carrier plate for picking up and positioning the male lens mold halves from the third carrier platen and positioning the male mold halves into the female mold halves in the first carrier platen, and a liquid delivery end effector mounted to the carrier plate for dosing a lens-forming material into the female lens mold halves;
• and
• a computer-automated control subassembly in electronic communications with the mold carrier-conveyor subassembly and with the three-dimensional pick-and-place subassembly.