The optical measurement algorithm for the real front and back surfaces of contact lenses from their center to periphery accurately and simultaneously is proposed. It is an algorithm that makes light incident vertically along the curved surfaces of contact lenses under the condition that the difference of curvature radii between the front and back surfaces is small enough within the NA of the optical probe. For this purpose, we adopted time-domain optical coherence tomography (OCT) with translation and rotation mechanisms. The shape, thickness distribution, and curvature radii of both surfaces were estimated with OCT signal analysis and circular approximation. The measured results were compared with the designed values and the measured data from a conventional shape measurement device. The curved shape of both surfaces and thickness were well matched with the designed values from lens center to periphery. In a curvature radius of the front surface, there was a proportional bias with a limit of agreement of − 0.77 % to − 2.09 % , and the correlation coefficient was 0.57. On the back surface, there was no systematic bias, and minimal detectable change was 0.178 mm, in a range of 95% confidential interval. The proposed algorithm well visualized the real shape and optical characteristics of the contact lens with enough accuracy to the design.

In recent years, with the development of precise lathe-cutting equipment, special shaped contact lenses (CL) have been crafted. However, while it is possible to manufacture such a lens, its shape evaluation has not been well-established. We conducted a basic optical experiment using special lenses to measure a spherical lens and nonspherical mold. As the measurement sample, a metal ball, special CL, and a toric-shaped mold were adopted. In order to accurately measure those real shapes, we proposed an algorithm in which the probe light is vertically incident to the sample surface within a numerical aperture of the optical probe. For this algorithm, we developed the specialized time-domain optical coherence tomography (TD-OCT), which was designed to conduct circular scanning while maintaining vertical incidence by driving a two-axis (vertical and horizontal) micro-electromechanical system mirror with a phase difference of 90°. The shape, thickness distribution, and curvature radii of both front and back surfaces of a CL were estimated with this OCT signal analysis and sphere fitting. The shape and curvature radius were evaluated by using the simulated data under the same experimental conditions. They were sufficiently accurate based on the resolution of this OCT. Also, a toric-shaped mold was evaluated by comparing the relationship between each coordinate and intensity of the interference signal. As a result, it is confirmed that the experimental result and the simulated matched well.

Recent advances in molding technology have enabled the fabrication of plastic molded components with complex geometries. In contact lens (CL) manufacturing, a double-sided molding process using resin molds is employed, in which the front and back surfaces of the lens are replicated through injection molding. However, thermal deformation during polymerization can alter the mold shape, thereby affecting the optical characteristics of the final lenses. This study proposes a high-precision optical evaluation method for resin molds used in contact lens (CL) manufacturing, utilizing a reflective wavefront sensor and optical coherence tomography (OCT). The wavefront sensor demonstrated high measurement accuracy (≈1/100λ) and reproducibility (≈1/200λ) as confirmed using reference samples, and yielded values of approximately 0.012–0.015 μm for the resin molds. Five mold designs with radii of curvature ranging from 6.500 to 8.500 mm were evaluated, revealing that Zernike coefficients varied depending on design and thermal treatment conditions. In particular, astigmatism (Z04) and coma aberrations (Z07) exhibited pronounced trends. A strong correlation was also observed between the Zernike coefficient Z07 and the mold thickness asymmetry measured by OCT. When the thickness difference increased by 2.3 times due to thermal treatment, Z07 increased to 1.9 times. In contrast, Z04 showed no consistent trend and exhibited significant variability (standard deviation > 0.5 μm) after polymerization. The proposed method enables precise detection of subtle shape variations and aberrations, providing valuable feedback for optimizing molding conditions and improving the quality of contact lens production. Furthermore, this method can also be applied to the quality evaluation of other optical components.

Injection molding is essential for mass-producing soft contact lenses, yet molding-induced deformation remains a decisive factor for optical quality. This study systematically evaluated the impact of resin mold design factors (optical zone (OZ) radius of curvature and resin mold thickness) and injection molding parameters (holding pressure and injection speed) on the properties of a dry-state lens (dry lens) using an L18 orthogonal array. The results demonstrated that optimizing the resin mold thickness to 0.9 mm reduced astigmatism by approximately 95%, while high holding pressure and low injection speed improved structural stability. Notably, the findings suggest that the refractive power of the dry lens is more strongly governed by macro-level curvature fluctuations and internal stress distributions arising from the resin mold thickness and shape than by the wavefront aberrations of the resin mold itself. Designs with a smaller radius of curvature (R = 6.5 mm) exhibited substantial power deviations of up to +2.8 D, whereas deviations remained within ±0.2 D for designs with a larger radius of curvature (R = 8.5 mm). For high-precision lens manufacturing, it is indispensable to incorporate a resin mold design that accounts for deformations induced during molding. This study provides comprehensive guidelines for achieving high-quality products by detailing the relationship between injection molding and design.