Ophthonix sends lenses to workstations using modular conveyors from Rexroth.

The 21st century, with its bright lights, all-day computing, 24-hour shopping and high-definition TV, places more stress on people’s eyesight than perhaps any other time in history. That’s why Ophthonix, Inc, a high-precision eyeglass manufacturer based in Vista, CA, embarked on a new technological process to create lenses offering more accurate vision correction.

With the appeal of better vision forming a solid foundation for continued growth, Ophthonix had definitive goals to ramp up its production capacity in planned phases. As a result, the company needed a facility that could be adapted easily to match their growing production volume.

With design, layout and integration help from Bridgman, MI-based Eagle Technologies, Ophthonix utilized a VarioFlow conveyor system and aluminum structural framing from Bosch Rexroth, Buchanan, MI. The goal was to implement a lean-based fully automated continuous-flow pull system that linked all facets of their production equipment. As a result, the Ophthonix lab is now equipped to move lenses to various workstations via a modular conveyor, without the need for constant employee input and monitoring, saving valuable time, resources and money.

High-definition lenses

Rexroth uses patented curve technology to reduce friction in curves, allowing trays to accumulate in the curve while using fewer drives to save on system costs.

Ophthonix produces iZon lenses, which are the first eyeglass lenses custom-made from an individual’s own iPrint, or unique optical fingerprint. The company’s iZon lenses essentially provide your eyes with a view comparable to watching high-definition television. They address the vision problems associated with microscopic irregularities, also referred to as higher-order aberrations. These aberrations impact how light passes through the eyes, and therefore, how well individuals are able to see.

For example, a person who has perfect 20/20 vision with conventional lenses may still experience blurriness around images, shadows, unclear vision at night, or glare and halos around lights as a result of these aberrations. By incorporating the iPrint into the iZon production process, the Ophthonix iZon lenses are able to address the symptoms associated with these distortions.

Unique structure; unique production needs

The iZon lens consists of three layers. The back layer is developed according to the patient’s iPrint and focuses on cylindrical correction. Ophthonix applies a unique algorithm to the iPrint to help determine this fit. The middle layer features a patented photo-refractive polymer, designed by Ophthonix. The front layer of the lens then completes the structure. The entire three-layer design contributes to the superior vision performance of the iZon lens.

With the Rexroth conveyors, standard robotic processing trays can accumulate in curves as they are routed to various stages of production.

Because the iZon lens is formed from a unique three-layer structure, it requires a special process to create it. When Ophthonix decided to create the lens, they discovered no other lab in the U.S. could handle the unique high-tolerance process. Therefore, they established a completely new lab, allowing them to oversee the entire production process. Rather than using conventional equipment, Ophthonix opted to use free-forming production machinery capable of cutting progressive lenses into complicated shapes and providing unmatched micron-level accuracy.

Ophthonix considered not only its current production needs, but also what it would need in the future. With a production curve planned to meet future volume requirements, Ophthonix chose a modular conveyor system that could be phased in and adapted to meet anticipated production increases without disrupting their entire operation.

The company partnered with Eagle Technologies and Bosch Rexroth to help design and integrate a fully automated lab. Because lab space is so expensive, Eagle recommended using the three-dimensional area in the 10,0002 ft. finishing lab, like a cube, to take advantage of vertical space. In addition to mapping out the layout, Eagle specified and built the conveyors, vertical buffer system, and a tray-up de-stacker to optimize the production process. They worked with Rexroth’s Linear Motion and Assembly Technologies group to source the modular VarioFlow conveyor system and the necessary aluminum structural framing.

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