Dipcoating thermoplastic spectacle lenses

Plastic injection-compression multi-cavity molding of flash-free improved cleanliness thermoplastic spectacle lenses (16) which are suitable for robotic dip hardcasting. Spring-loaded (25,26) molds (13,14) having variable-volume cavities are used in an injection-compression molding process to form, without parting line flash, pairs of a wide range of differing optical power polycarbonate prescription spectacle lenses (16). These pairs have molded-on design features which are specifically suited for full automation of the process, starting with ejection out of the mold into a takeout robot (43,60) whis is integrated via full automation with a subsequent dip hardcoating A molded-on tab (1,3,4) with each pair of lenses (16) is specifically suited for manipulation by SCARA-type robot (43,60). This combination produces micro-clean hardcoated, paired molded lenses made entirely within a single cleanroom air enclosure, without any human operators therein, and without requiring any cutting or trimming of the molded lens pair or runner system before hardcoating or the use of FREON™ CFC or aqueous cleaning protocols before dip hardcoating.