Contact Lens Mould And Methods

A method of making a contact lens comprising:

• providing a first mould half shaped to provide the front surface of the contact lens and a second mould half shaped to provide the rear surface of the contact lens wherein the first and second mould halves form a mould cavity, wherein the first mould half has a first rim and the second mould half has a second rim, and the first and second rims fit together to provide a seal for the mould cavity, wherein the first rim is inclined at an angle of x relative to an axis passing through the centre of the first and second mould halves, wherein x is from 30 to 60°, and wherein the second rim is inclined at an angle of x-y relative to the axis passing through the centre of the first and second mould halves, where y is from 0 to 4°, and wherein the first and second rims provide a guide for the mould halves;
• introducing a contact lens monomer composition into the first mould half;
• mating the first and second mould halves, wherein the first and second rims guide the mould halves together;
• curing the monomer composition to form a contact lens.

A method of making a contact lens mould comprising a first mould half and a second mould half, the method comprising:

• forming a first moulding insert for a first mould half;
• fitting the first moulding insert into a first master mould;
• forming a second moulding insert for a second mould half;
• fitting the second moulding insert into a second master mould;
• forming a first mould half in the first master mould;
• and
• forming a second mould half in the second master mould,
• wherein at least one of the first or second moulding inserts is formed using a diamond lathe tool with a tip of radius less than 3 μm.