What manufacturing process is most commonly used for disposable contact lenses?

The manufacturing process most commonly used for disposable contact lenses is cast molding. This method allows for the efficient and cost-effective production of large quantities of lenses, which is essential for the high-volume demand associated with disposable options.

In cast molding, the lens material is typically placed in a mold, and then heat and pressure are applied to shape the material into the desired lens form. This process not only produces lenses with great accuracy and consistency in thickness and curvature, but it also facilitates the incorporation of various optical features, such as multifocal designs.

While lathe cutting is a precision technique often used for custom or specialty lenses, it is not practical for mass-production disposable lenses due to longer manufacturing times and higher costs. Spin casting and injection molding are techniques utilized in different contexts; however, they are less suited for the specific requirements and designs of contact lenses when compared to cast molding. Therefore, cast molding stands out as the preferred choice for the production of disposable lenses.