Design build test cycle reduction

An ophthalmic lens design and modeling system comprising:

• a) means generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components required for lens manufacture in an ophthalmic lens manufacturing system and wherein said means generating a user interface display device provides functionality for specifying expansion and shrinkage factors associated with manufacture of said lens design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated, wherein a template comprises manufacturing data associated with a lens design including machining data and engineering drawings, said manufacturing data available as direct input to an ophthalmic lens manufacturing system for driving the lens manufacturing process necessary to achieve a particular lens design and wherein associated manufacturing components for said lens include one or more lens mold and mold inserts used in lens mold manufacture, said template further comprising manufacturing data for enabling manufacture of one or more lens mold according to lens mold designs associated with a particular lens design, and, manufacture of mold inserts according to mold insert designs, each said lens mold and lens mold design accounting for process parameter variations by specified linking information;
• b) means generating linking information for governing physical behavior of lens design features included in said template in accordance with one or more process parameters affecting lens manufacture and manufacture of associated components in an ophthalmic lens manufacturing system;
• c) means for utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system, wherein use of said template and design and linking information therein facilitates rapid lens modeling and lens manufacturing operations with greater accuracy, thereby reducing lens design build and test (DBT) cycle time, wherein said lens design data comprises one or more of:
• text file or an electronic file representing an output of a three-dimensional computer aided design (CAD) system;
• d) memory storage means for storing templates that have been generated, said use interface means providing functionality for accessing stored templates;
• and
• e) editing means enabling a user to modify lens, lens mold, mold insert, template design information and linking information provided with a template to create a new lens, lens mold, mold insert, template design, said memory storage means defining a catalogue of developed templates that may be accessed and re-used for producing new lens designs wherein said lens design information comprises one or more equations utilizing process parameters that govern lens manufacturing operating conditions, said equations provided for linking the lens design with the manufacture of a back curve (BC) lens mold;
• linking the lens design with the manufacture of a front curve (FC) lens mold;
• and, linking the manufacture of a BC and FC lens mold with a resultant physical lens mold assembly, and then the insert pair designs of BC and rear core insert, and FC and front core design;
• wherein said lens design information comprises one or more equations utilizing process parameter is that govern lens manufacturing operating conditions, said equations provided for:
• linking the lens design with the manufacture of a back curve (BC) lens mold;
• linking the lens design with the manufacture of a front curve (FC) lens mold;
• and, linking the manufacture of a BC and FC lens mold with a resultant physical lens mold assembly, and then the insert pair designs of BC and rear core insert, and FC and front core design.

A method for designing and modeling ophthalmic contact lenses comprising the steps of:

• a) generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components comprising at least one of:
• a lens mold an insert and a core
• b) generating a 3D model of the lens and the associated components;
• c) receiving data descriptive of a change of a manufacturing process parameter based upon data descriptive of operating conditions of a manufacturing line, said process parameter comprising at least one of:
• shrinkage of plastic from an insert and hydration of contact lens monomer;
• d) generating linking information for governing physical behavior of lens design information included in said template in accordance with one or more process parameters affecting lens manufacture and manufacture of associated components in an ophthalmic lens manufacturing system;
• e) modifying design information via the linking information and based upon the data descriptive of a change in a manufacturing process parameter;
• f) generating a revised 3D model of the lens and the associated components, based upon the modified design information;
• and
• g) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system.

A method for designing and modeling ophthalmic contact lenses comprising the steps of:

• a) generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components required for lens manufacture in an ophthalmic lens manufacturing system, wherein associated manufacturing components for said lens include one or more lens mold and mold inserts used in lens mold manufacture, said method further including;
• utilizing manufacturer data in said template for enabling manufacture of one or more lens mold according to lens mold designs associated with a particular lens design, and, manufacture of mold insert according to mold insert design, each said lens mold and lens mold design accounting for process parameter variations by specified linking information and wherein said generated user interface display device provides functionality for specifying expansion and shrinkage factors associated with manufacture of said design as performed by said ophthalmic lens manufacturing system, whereby specified changes to said factors are automatically reflected in resultant 3D models generated and wherein a template comprises manufacturing data associated with a lens design, said method including the step of directly inputting manufacturing data available from said template to an ophthalmic lens manufacturing system for driving the lens manufacturing process necessary to achieve a particular lens design;
• b) generating linking information for governing physical behavior of lens design features included in said template in accordance with one or more process parameters affecting lens manufacture and manufacture of associated components in an ophthalmic lens manufacturing system;
• c) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system, wherein use of said template and design and linking information therein facilitates rapid lens modeling and lens manufacturing operations with greater accuracy, thereby reducing lens design build and test (DBT) cycle time;
• and
• d) storing each template that has been generated, said user interface display providing functionality for accessing stored templates;
• and, modifying or editing lens, lens mold, insert and template design information and linking information provided with a template to operate a new lens design, said memory storage means defining a catalogue of developed templates that may be accessed and re-used for producing new lens designs;
• wherein said lens design information comprises one or more equations utilizing process parameters that govern lens manufacturing operating conditions, said equations provided for:
• linking the lens design with the manufacture of a back curve (BC) lens mold;
• linking the lens design with the manufacture of a front curve (FC) lens mold;
• and, linking the manufacture of a BC and FC lens mold with a resultant physical lens mold assembly, and then the insert pair designs of BC and rear core insert, and FC and front core design.

A program storage device readable by a machine, tangibly embodying a program of instructions executable by the machine to perform method steps for designing and modeling ophthalmic contact lenses, said method comprising the steps of,

• a) generating a user interface display device providing functionality for generating a template associated with a desired lens design to be manufactured, said template comprising design information sufficient for generating three-dimensional (3D) models of lens, and 3D models of associated components comprising at least one of:
• a lens mold, an insert and core;
• b) generating a 3D model of the lens and the associated components;
• c) receiving data descriptive of a change of a manufacturing process parameter based upon data descriptive of operating conditions of a manufacturing line, said process parameter comprising at least one of:
• shrinkage of plastic from an insert and hydration of contact lens monomer;
• generating linking information for governing lens design information included in said template in accordance with one or more process parameters affecting lens manufacture and parameter affecting manufacture of the associated components in an ophthalmic lens manufacturing system;
• e) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system, wherein use of said template and design and linking information therein facilitates rapid lens modeling and lens manufacturing operations with greater accuracy, thereby reducing lens design build and test (DBT) cycle time
• e) modifying design information via the linking information and based upon the data descriptive of a change in a manufacturing process parameter;
• f) generating a revised 3D model of the lens and the associated components, based upon the modified design information;
• and
• g) utilizing lens design data and said linking information from said template for driving lens manufacture of the associated lens design in an ophthalmic lens manufacturing system.

An ophthalmic lens design system comprising

• a) means generating a user interface display device providing functionality for designing an ophthalmic contact lens and associated components required for manufacture of that lens by an ophthalmic lens manufacturing system and generating design information that is stored in a database accessible by a user via said interface;
• b) means for automatically generating a three-dimensional (3D) model of said ophthalmic contact lens and models of each of associated components required for manufacture of that lens, and displaying said 3D model via said user interface;
• c) means for manipulating said 3D models via said user interface for modifying lens design features and features of associated components required for manufacture of that lens design as required for optimizing said lens design;
• d) means for automatically updating design information of the lens and the all of associated components based upon the manipulation of a 3-D model of one or more of the lens and the components;
• d) means for generating lens design data and data governing design of associated components thereof for storage in said database, and automatically updating data as said 3D models of said lens design and associated components are manipulated by said user;
• and,
• e) means capable of automatically generating manufacturing data from said stored data, said generated data functioning as direct input to said ophthalmic lens manufacturing system for driving the lens manufacturing and associated component build processes necessary to achieve the associated lens design, wherein modeling and lens manufacturing operations are performed with greater accuracy in less time.