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Sunglass lenses are more than just a stylish accessory, they are a crucial component in protecting our eyes and enhancing visual clarity.
At The Sunglass Fix, we take pride in producing high-quality replacement lenses that are durable, optically clear, and built to last. In this article, we’ll take you through the meticulous process of how sunglass lenses are made, from manufacturing to quality control, showcasing the steps we take to ensure every lens meets the highest standards of excellence.
Manufacturing of Sunglass Lenses
The lens production process begins with our expert manufacturers crafting high-end sunglass lenses from polyamide/nylon materials. These lenses undergo precision tinting and are coated with layers to enhance optical clarity, protect against wear, and sometimes include anti-reflective coatings.
Over the years, we’ve worked closely with our manufacturing partners to refine production techniques. When issues arise, we work together to implement improvements, such as adding protective layers. This commitment ensures our lenses are durable, clear, and built to last.
Order Processing and Preparation
Once a customer places an order, the in-house process begins. Orders are handled daily, following a first-in, first-out approach.
To prepare for production, trays are loaded with essential components. Fresh blocking pads are placed on the trays to ensure lenses are correctly centered and aligned during the process, especially for polarization and gradient designs. Accessories such as nose pads, pack slips, and barcode sheets are added to each tray, making them ready for automation.
The prepared trays are stacked in groups of nine and placed onto conveyor belts, where they enter the production workflow. From this point, the trays move seamlessly through the automated system for lens selection and customization.
Automated Lens Picking Process
The automated workflow begins with the trays entering the picking machine. This machine uses barcode scanning to identify the specific lenses required for each order, ensuring precision and accuracy. It selects a left and right lens, placing them onto sticky blocks positioned in the center of the tray to maintain proper alignment for production.
To match the customer’s order, lenses are selected based on their type and color, such as polarized, BIO Polarized, or regular lenses. The picking machine organizes and mounts the lenses onto the trays, preparing them for the next stage: edging and shaping.
By automating this step, the process ensures efficiency and minimizes errors, making it possible to handle high volumes of orders while maintaining the lenses quality.
Edging and Shaping Lenses
After the lenses are mounted onto trays, they are moved through a robotic handling system to the edging machine. A barcode scan provides the shape and design specifications required to fit the customer’s selected frames. Robotic vacuum arms precisely place the lenses into the edging machine, where they are milled down to the exact size.
The edging process typically takes 1 to 3 minutes per lens, depending on the design's complexity. For advanced customizations, such as drill holes, nylon grooves, or stepped bevels, additional time and precision are required. Our system can achieve a remarkable accuracy of 0.05mm, ensuring a perfect fit for virtually any sunglass frame, excluding single-piece or goggle lenses.
Once edged, the left and right lenses are returned to the tray and prepared for quality control, where they undergo further inspections and refinements if necessary.
Quality Control and Inspection
After the lenses are shaped, they are thoroughly inspected to ensure they meet the highest quality standards. During the inspection, any rough edges or imperfections are addressed, with additional handwork applied to refine complex designs and achieve a neat, polished finish.
Lenses are carefully examined for scratches, defects, or inconsistencies that could compromise their performance or lead to customer dissatisfaction. Only lenses that pass these rigorous quality checks proceed to the final stages of production.
This meticulous attention to detail ensures that every lens not only fits perfectly but also delivers exceptional optical clarity and durability, meeting the expectations of our customers.
Packaging and Shipping
Once the lenses pass quality control, they are cleaned, polished, and given a final inspection to ensure they are free from scratches or defects. After meeting our strict standards, the lenses are carefully packed using 100% recyclable materials to promote sustainability. Each pair is placed in a clean and secure cardboard box designed to protect them during transit.
Shipping labels are then printed, and the packages are sorted into larger boxes for collection by our courier. This efficient system ensures that orders are shipped promptly and reach customers in perfect condition, no matter where they are in the world.
Bringing New Life to Your Sunglasses
The journey from raw materials to finished sunglass lenses is a detailed and carefully controlled process. At The Sunglass Fix, every step is carried out with precision and care. This commitment ensures that the lenses we produce are not only durable and optically clear but also crafted to meet the unique needs of every customer.
If your sunglasses are scratched or damaged, there’s no need to replace the entire pair. Our premium replacement lenses offer a cost-effective and eco-friendly solution to breathe new life into your favorite frames. With free worldwide shipping and a dedication to quality, The Sunglass Fix makes it easy to restore your sunglasses and keep them looking and performing their best.
