The eyewear manufacturing process from design to finishing

The eyewear manufacturing process from design to finishing

25-04-29 19:19:11    By Bestsea eyewear

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The glasses manufacturing process from design to finishing

1. Glasses conception is to determine the design direction and ensure that the product meets market demand. The picture below is a conception of glasses design. It is a square, men's, luxurious, acetate sunglasses. Global trend research. Analyze the popular trends of international eyewear exhibitions such as Milan MIDO and Paris Silmo, and predict the design trends in the next 1-3 years. 1.1  Consumer preference analysis. Study user preferences through big data such as social media, e-commerce platforms, Google Trends, etc., such as retro style, minimalism or technological design. 1.2 For different markets, through Google, e-commerce and other platforms, study the market's hot-selling styles, colors, styles, etc., and seek design inspiration. By studying the hot-selling models of different eyewear brands, find differentiation and then find design points. 2. Glasses design. The design phase is a crucial step to achieve results that reflect the style and iconic elements of a brand. Throughout the process, our designers must work closely with the client's creative team. After developing multiple ideas and proposals, we both reach a consensus on one design that best expresses manufacturing excellence, and complete the final design prototype with our innate ability to judge fashion trends and evolution. Glasses conception is an abstract concept, and design is to transform abstract concepts into visual expressions. Collect colors, materials, cultural elements such as architecture, other products, natural textures, etc. to form the design tone. Then, through hand-drawn sketches or computer drawings, the abstract concept is expressed in the form of a visual design diagram. Generally speaking, the design elements of glasses generally include the following aspects: 2.1 Frame shape, mainly square, round, rectangular, oblong, oval, cat's eye, pilot shape, heart shape, butterfly shape, geometric shape, geometric shape, etc. 2.2 Material matching, the material matching of glasses directly affects the wearing comfort, durability, weight and style performance. Usually, the frames and lenses of glasses are made of different materials. Common glasses materials are acetate, metal, titanium, plastic and some natural materials such as bamboo, wood, horn, etc. 2.3 Color matching. Color matching should be carried out according to the target consumer group. There are many colors that can be used, such as black, gold, rose gold, silver, gray, transparent, translucent, tortoise shell, red, blue, green, off-white, light pink, and various pattern colors. Design concept: The design of this pair of women's cat-eye sunglasses is inspired by a deep exploration of fashion and personality, aiming to create an accessory that is both classic and modern. The frame uses a multi-color patchwork process, and the dark purple and pink are combined in a unique shape, like an artistic brushstroke, which is delicately embellished at the top. The concave and convex effect is created through fine carving, and the clever use of the beveled edge contour makes the overall shape present a layered three-dimensional sense, as if it jumps out of the plane, with great visual impact. The temple part continues the patchwork design, and at the same time incorporates a concave and convex texture, which echoes the frame, like a harmonious movement, enhancing the overall visual coherence. This design not only shows the classic elegance of cat-eye glasses, but also incorporates modern fashion elements into it. Every detail has been carefully considered. Whether it is worn daily or attending fashion events, it can make the wearer exude unique charm and become the focus of everyone's attention. The picture below is from BESTSEA's latest luxury acetate sunglasses design. Design concept: The design of this pair of sunglasses is inspired by the cross-border integration of modern architectural aesthetics and high-end fashion. With "three-dimensional sculptural sense" as the core language, the visual tension of optical accessories is reshaped through precise structural deconstruction. The frame is made of two-color materials. The collision of black and transparent acetate fiber forms a staggered layer of light and dark. The inner beveled surface that runs through the top of the temple extends to the temple joint at an acute angle of 15 degrees, strengthening the three-dimensional outline like the suspended structure of deconstructionist architecture. The hyperbolic material process of the temple is not only ergonomic, but also the transparent material with gradual thickness treatment forms a material dialogue with matte black. It is equipped with a decorative art style patterned gold copper needle, and its spiral pattern is inspired by the metal relief process in the decorative art movement in the s. The two gold-plated rivets located at the hinge of the frame are not only functional reinforcements, but also echo the futuristic tone of the overall design in the form of geometric dots. The whole work interprets the modern and luxurious wearing art in a combination of rigidity and softness through the trio of material hedging, angle cutting and precious metal inlay. 3. Prototyping of glasses. At this stage, our craftsmen put in a high level of energy, processing and attention to detail in the most precise way. After making the first model, which is technically called a "sketch", the real prototyping stage begins. For each product, the prototype development team will produce a physical object. The result of this process is the first frame in a series. The production of glasses samples is a bridge between design and production, and it is necessary to balance creativity and process feasibility. When making samples, 3D printing technology and traditional manual glasses production processes can be used. Both methods have their own advantages and disadvantages. 3D printing is fast, but the surface is relatively rough and the color is very single. The advantage of traditional glasses production is that it can produce samples with complex structures and diverse colors. The disadvantage is that it takes a long time and grows high; before mass production, it is necessary to strictly test the structural stability and wearing comfort. 4. Glasses materials and colors. The materials used in each product series are different, all based on customer requirements, the specific needs of a particular design, and the adaptability of the material itself to the processes required to make different frames. Our designers will work together to study plastics, precious metals, and bio-based materials, interpreting current trends through color and color matching, and predicting future aesthetic appearances. With the continuous development of material technology and processes, the materials and colors of glasses are becoming more diverse. Common glasses materials include acetate, metal, titanium, plastic, and some natural materials such as bamboo, wood, and horns. The most suitable materials and colors should be selected according to different designs, structures, and cost requirements. For material colors, please refer to our website: Acetate color: https://www.bestseaeyewear.com/cellulose-acetate-material/ Sunglass lens color: https://www.bestseaeyewear.com/Sunlens/ Metal color process: https://www.bestseaeyewear.com/metal-plating-color/ 5. Glasses production. The production of each pair of glasses requires at least more than a hundred different processes, which are carried out by skilled craftsmen in different production lines. Together with technicians, they strictly follow each step to ensure that every detail is transformed into a unique element of the glasses produced. Each department of our glasses factory is equipped with important technical equipment, such as high-precision automatic and semi-automatic machines and processing devices for milling front frames, lenses and components. To ensure the quality of the entire process and the final product, each step of the production process is strictly controlled. Production of frames. Metal frames are formed by CNC cutting and laser welding; plastic frames are high-temperature finalized after injection molding, and springs are added to the hinges to enhance durability. Sheet glasses go through CNC cutting, rollers, hinges, polishing, assembly and other processes. Finally, each pair can be shipped after a detailed inspection. For more details about eyewear production, please refer to our related articles: Production process of acetate glasses: https://www.bestseaeyewear.com/product-knowledge/2.html Production process of metal glasses: https://www.bestseaeyewear.com/product-knowledge/metal-eyewear-production.html 6. Adjustment and quality control. Before the end of the entire processing process, the glasses will enter the adjustment stage. All components of optical glasses and sunglass frames, from finishes to lenses, are checked piece by piece to ensure their basic characteristics, among which fit is one of the most critical performances. Adjustment mainly includes the following aspects. Frame adjustment: Manually calibrate the opening and closing of the temples and the height of the nose pads to ensure a stable and comfortable fit. Lens positioning: Check the alignment of the optical center and the pupil to avoid visual distortion. Comprehensive quality inspection includes the following aspects. Frame: Check the flexibility of the hinges and the surface process (no scratches/paint peeling). Lens: The focal meter verifies the degree, astigmatism accuracy, and the coating is flawless. Fit: Simulate wearing test to ensure that the frame fits the face shape and does not slip. For more details on adjustment and quality control, please refer to our related articles: How to adjust your glasses: https://www.bestseaeyewear.com/product-knowledge/adjust-eyewear.html How to inspect our glasses: https://www.bestseaeyewear.com/industry-news/eyewear-quality.html How to inspect the quality of sun lenses: https://www.bestseaeyewear.com/industry-news/sunlens-quality.html 7. Packaging of glasses. Finally, each pair of glasses will be packed in the brand's specific packaging to prepare for shipment. Glasses packaging not only protects the product from damage during transportation, but also the first impression of the brand image. Good packaging can prevent dust and scratches, prevent deformation of the frame, and at the same time improve the unboxing experience and strengthen consumers' trust in quality. High-end packaging also comes with accessories such as cleaning cloth and warranty card to increase added value. 8. Shipping of glasses. After all the goods are prepared, they are sent to the customer's designated delivery address. The above links are the entire glasses manufacturing process from design to finishing. The conception of glasses, turning abstract ideas into visual designs, making samples of design deformation objects, and then to production and processing, comprehensive adjustment and quality inspection, packaging and shipment.

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These days, the production process for spectacle lenses is largely automated. Once the optician has sent the patient's lens order to ZEISS, the first production step begins: the individualised lens is calculated and the data required for manufacturing the lenses is made available. Each production order is assigned a bar code so that the data necessary for processing the lens can be identified at each station in real time and then loaded to the particular processing station.

Depending on the prescription, the semi-finished lenses are selected automatically in the warehouse. The semi-finished lenses for the left and right eye already have an optical power on the front surface. To create the wearer's prescription, only the back surface is machined with ZEISS freeform technology. The semi-finished lenses – also known as "pucks" because of their shape – are automatically taken from the warehouse and placed in a tray. Then the journey begins: conveyor belts transport the tray from one station to the next until ultimately two spectacle lenses have been created.

Once blocking is complete, the lens is formed to give it the desired shape and prescription. With ZEISS freeform technology, the front surface of the semi-finished lens already has the corrective optical power when taken from the warehouse. Only the back surface still needs to be machined and shaped for the particular wearer. To do this, a 5-axis CNC method is used that creates the right shape and prescription for the wearer in around 90 seconds. Basically, three different steps are performed within a minute and a half: the lenses are roughened, given a general shape and then tens of thousands machining points are defined using a natural diamond. This method enables the manufacturer to freely customise the optical surface, i.e. freeform.

During polishing, the surface of each lenses is polished while the optical properties remain unchanged. A perfect surface is important for the application of modern lens coatings that do not separate from the lens. Every ZEISS lens gets its own special signature: a laser is used to engrave a nearly invisible "Z" in the lens. This precisely positioned marking is important for quality assurance and affixing a stamp that later assists with grinding and centring the lenses.

Now the lens is de-blocked, i.e. carefully removed from the blocker. Since the metal alloy connecting the lens to the blocker melts at just under 50° C, it is simply dipped into hot water. The lens is then cleaned much like a car at the car wash: brushes, different cleaning agents and ultra-pure (i.e. especially well-treated) water is used to remove any traces from the lenses and prepare them for coating. The lenses are then blow-dried. Environmental protection is a matter of course at all production facilities: materials like the metal alloy are treated and reused, and the water required for production is recycled in an environmentally friendly manner.

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At this stage, the lenses are tinted if requested. Plastic lenses are placed in a dip dye batch, while glass lens tints are applied in metal oxide layers.

Textile colours that do not pose any risk to human health or the environment are used for plastic lenses. This process requires great dexterity: since each lens is manufactured individually and ZEISS offers tints in any colour, a lot of experience is necessary to achieve the "right" tint.

Now comes the final step in the production process, which is the most demanding technologically: the application of a spectacle lens coating.  Coatings make the lens scratch-resistant and durable, help ensure crystal clear vision when it's windy or in inclement weather, repel dirt, reduce irritating reflections and offer many functional benefits, such as when a person is driving or working at the computer. Unlike their glass counterparts, plastic lenses are not adequately scratch resistant on their own. Thus a suitable hard coating to protect against scratches is always a must for ZEISS plastic lenses. This is applied as a lacquer to the plastic lens in the dipping process, hardening it. Which of the various specially customised lacquers are used depends on the plastic and thickness of the lens. After ultrasonic cleaning, the next coating is added by applying anti-reflective layers in a vacuum deposition process – and we do mean layers, because a modern lens can have up to nine. The final layer of coating gives the lens its extremely smooth surface, making it particularly resistant to both dirt and water.  

The lenses are almost done. But do they meet ZEISS' strict quality assurance requirements? To ensure they do, each lens is thoroughly inspected before delivery. A visual inspection is performed to check for dust or damage, as well as a mechanical one to ensure that each lens meets the necessary specifications. Are the dioptres, the axis, cylinder, thickness, design and diameter correct? If the lens is flawless, then it is "stamped" in the final step. This orientation stamp is used to align the lens and assists the optician with inserting it into the frames precisely. It is removed before the final pair of glasses is dispensed to the wearer.

The Z for ZEISS is  only engraved once all the quality assurance steps have been successfully completed and the lens really does feature ZEISS quality. The Z is our signature – our quality promise inscribed into every individual lens.
And anyone who wants a unique label in the spectacle lens can have their initials engraved!

Fun fact:  did you know that only women work in the ZEISS tinting department? The reason: women tend to have better colour vision than men, making them extremely good at identifying slight deviations from the norm.

Contact us to discuss your requirements of Eyewear Manufacturing Process(ja,uk,es). Our experienced sales team can help you identify the options that best suit your needs.