FEA Industries, Inc. | Focused on Technology

STAGE 1– Lens Surfacing

Here is where we take semi-finished lenses and work the prescription into the back of the lens. This could be any type of lens – single vision, bifocal, progressive, or free-form. They all go through a similar process as is described step-by-step below. There are also various checks in the process to ensure a quality result.

The Taping Process: After the correct lens blanks are selected, they are sent to have a protective tape applied to their front surface.; Watch the video
The Blocking Process: After going through the taping process, an alloy block is next affixed to the front surface of the lens.; Watch the video
The Generating Process: Having had an alloy block affixed to it the lens is then on its way to the generator where it will begin the cutting process.; Watch the video
The Polishing Process: After being cut on the generator it is necessary for the lens to be polished. During this step we polish the back of the lens to give it a smooth and even surface. This ensures an optimal patient experience with little visual distortion.; Watch the video
The Engraving Process: Laser Engraving: For free-form lenses, we make use of a laser to micro-engrave fitting marks into the lens.; Watch the video; Mechanical Engraving: At FEA we make use of Optotech OME80s for our mechanical engraving. These machines are able to process up to 120 lenses per hour and can be used to engrave plastic lenses. This speed allows us to process jobs through engraving more quickly and with the precision and accuracy of a computer run machine.; Watch the video
The De-Blocking Process: After going through all the preceding steps, it is time for the lens to be removed from the alloy block that was applied to it earlier in the lens surfacing process.; Watch the video
The Tape Removal Process: After removal from the alloy block, it is time for the lens to have its protective tape removed.; Watch the video
The Lens Printing Process: Finally we come to the last step in the lens surfacing process. After having been de-blocked and having its protective tape removed we send the lens through the printing process. It is here that we re-apply ink fitting marks to the front of the lens for inspection and edging.

STAGE 2– AR Coating Process

Here at FEA we make use of our in-house AR coating clean room. After traveling through the surfacing process, any lens receiving an AR Coating will eventually find its way to this room. Once here the lens is processed and is run through one of our two thermal dip coating machines. After exiting the dip coating machine the lens then enters the drying/holding oven phase and is finally placed into one of our two on-site AR coating machines. After this the lenses then go through our AR inspection process before moving on from this area.

STAGE 3– Quality Assurance

Quality Assurance is an ongoing part of the life of a lens. It isn't just a single step at the end. In order to ensure that our products stay correct and consistent, we strive to make quality our top priority. This involves not only reactive QA, such as checking lens powers and quality, but proactive QA as well. This type of QA involves running tests at scheduled intervals, and is about identifying problems while they are small, and not waiting to fix things until they break.

Freeform Measuring Machine: At FEA we make use of an OptoTech OMM60 Freeform measuring machine during our QA process. This machine utilizes measuring software that is able to compare the processed lens with the theoretical map generated by the input of the patients prescription. In addition to this software the machine makes use of a high precision measuring pin which can measure with an accuracy of +/-1µm. This level of precision allows us to be sure that the lenses we send out are the lenses that match the prescription submitted with the order.; Watch the video
Digital Microscopes: At FEA we make use of digital microscopes in our Quality Assurance process. These microscopes help us analyze lenses with problems to see if the issue with them is being caused by surface defects that are not readily apparent to the naked eye. It is by using these microscopes that we are able to identify surface defects that might impact the quality and/or longevity of the lens.
Weather Testing: Weather can effect everything in our world, including lenses and the coatings we apply to them. It is because of this that we have need of tests that can simulate the effects of varying weather on our products.; Watch the video
Adhesion Test: At FEA we make use of the Adhesion test when it comes to testing our AR. This test, which we nick-name the Freddy Krueger Test, involves etching a cross hatch pattern on the lens using a series of blades and then submerging the lens in boiling water. The lens is then removed from the water and tape is applied to the front of the lens and then removed and examined, as well as the lens itself to see if any changes have occurred on the lens.
Photo Spectrometer: After every AR Run is completed we subject the lenses in that run to testing using a photo spectrometer. This device uses sensors to read the lens and detects any potential irregularities in the lenses dip coating. In addition to this, the photo spectrometer tests the wave length of the AR used to coat the lens to make sure that it falls within the acceptable range.; This machine is used to test every run after it is finished for quality assurance purposes.
FocoVision Lens Inspection: In addition to our AR Dual Lens Mapper we also make use of AR FocoVision lens mappers in our quality assurance process. The benefits of this machine are numerous and can be seen in the video below.; Watch the video
Dual Lens Mapping: At FEA we make use of an AR Dual Lens Mapper to test for quality assurance on our lenses. This machine lets us catch errors in the lens by comparing the actual lens surface against the design for the lens which enables a detailed error map to be created and then used to fix the errors. The benefits of this machine are that it is not dust-sensitive and it uses no physical contact with the lens while making the measurement which helps reduce the chance of erroneous error and measurement generated errors or imperfections.

STAGE 4– Finishing

Here is where we cut lenses into their final shape and insert into the frame. Here we again strive to be as efficient as possible. Some of our machines, such as the MEI Bisphera, is not only able to cut up to a pair of lenses per minute, but also double-checks the power of the lens before cutting. This gives us an additional safety check to prevent any accidental mix-ups, and keep production flowing.

Tracing: A frame tracer uses a metal stylus to trace the inside of a frame. This allows a digital image of the frame shape to be constructed so that the edging machinery can cut the lens to the proper shape for the frame. At FEA we process a wide variety of order types, some are rimless orders, others are regular metal or plastic frame orders, the range goes on and on.
Blocking: To properly orient the lens in the machinery, a plastic block is attached to the front of the lens. This is held in place by a double-adhesive blocking pad. The blocker projects an image of the frame shape to allow the operator to properly align the lens.; Watch the video
AIT Edger: When it comes to glass lenses you cannot use the same edgers you would use for other lens materials. This is because the different materials need to be edge by wheels of different materials. As such while we utilize other edgers for most materials we make use of special AIT edgers for all of our glass jobs.
ES-4 Edger: The ES-4 is a high production industrial edger with the ability to process small B measurements. Along with the MEI Bisphera we utilize it for the edging of lens order. The ES-4 is quick and efficient, processing up to 90 lenses per hour.; Watch the video
MEI Bisphera: The MEI Bisphera is one of two machine models we use here at FEA. It is able to edge up to a pair of lenses per minute, the MEI Bisphera-XDD is one of the fastest edgers available.; Watch the video

FEA Industries, Inc. | Independent Wholesale Optical Laboratories

Technology at FEA

Manufacturing Process

STAGE 1– Lens Surfacing

STAGE 2– AR Coating Process

STAGE 3– Quality Assurance

STAGE 4– Finishing