Sky Bloom IT
In the eye-care industry, lens quality defines user experience. From eyeglasses and contact lenses to intraocular lenses used in surgery, every product must meet rigorous clarity, curvature, and cosmetic standards. Even minor scratches, inclusions, or warping can lead to discomfort, visual distortion, or product rejection.
As traditional manual inspection methods struggle with consistency and scale, manufacturers are rapidly embracing automated inspection systems to uphold precision and regulatory compliance.
Intelgic, with a vision of zero defect manufacturing using machine vision for quality assurance, has developed a specialized lens inspection automation machine that empowers manufacturers to detect minute defects in ophthalmic lenses with exceptional speed and accuracy. Using a synergy of high-resolution optics, adaptive lighting, Z-axis motion control, and AI-driven software, Intelgic’s system delivers reliable, scalable, and fully traceable lens inspection for modern production lines.
What Makes Lens Inspection So Challenging?
Ophthalmic lenses are not like other parts—they are transparent, curved, coated, and highly sensitive to even sub-micron surface irregularities. Key inspection challenges include:
- Transparency: Makes defect visibility difficult under conventional lighting
- Power Variation: Curved surfaces require dynamic focusing and imaging adjustments
- Surface Coatings: Anti-reflective, UV, or tinted coatings interfere with detection
- Fine Defect Size: Defects are often smaller than 30 microns
- Subjectivity in Manual Inspection: Inconsistent detection due to human fatigue and error
Intelgic’s Lens Inspection Solution
Intelgic’s system is purpose-built to inspect every type of eye-care lens with high fidelity and zero subjectivity.
Core Components:
- Multi-Angle Lighting Geometry
Uses specialized low-angle, coaxial, and backlighting techniques to highlight invisible defects. - Precision Camera Optics
Employs high-resolution area-scan cameras with macro or telecentric lenses to ensure uniform magnification and clarity. - Dynamic Z-Axis Focus Control
Automatically adjusts camera position to maintain sharp focus across different lens thicknesses and diopters. - AI-Powered Defect Analysis
Detects and classifies cosmetic and structural defects, such as:
- Hairline scratches
- Black spots and particles
- Edge chipping and cracks
- Surface waves
- Coating inconsistencies
- Contaminants and residues
- Hairline scratches
- Configurable Inspection Recipes
Enables setup of inspection logic based on lens type, geometry, and acceptance criteria. - Real-Time Reporting & DQC Generation
Outputs inspection logs, annotated images, pass/fail decisions, and Digital Quality Certificates for each lens.
Types of Lenses Supported
| Lens Category | Common Inspection Needs |
| Single Vision Lenses | Surface clarity, scratch detection |
| Progressive & Bifocal | Curvature consistency, wave defects |
| Tinted & Photochromic | Uniform color density, coating finish |
| Contact Lenses (Soft/RGP) | Bubble detection, edge defects |
| Intraocular Lenses (IOL) | Biofilm residues, concentricity, particulate detection |
Key Benefits
- Detection of Micron-Level Defects
Spot defects smaller than the eye can see, improving quality assurance. - Repeatable Accuracy Across Shifts
No operator variability—perfect consistency in every inspection cycle. - Rapid Cycle Time
Capable of inspecting 3–6 lenses per minute depending on setup. - Cloud or On-Prem Integration
Supports centralized dashboards, historical data access, and KPI tracking. - Regulatory Readiness
Compatible with ISO 14889, ISO 8980, CE, and FDA standards for optical lens production.
Optional System Enhancements
- Robotic Lens Handling – Fully automated pick/place and conveyor-fed loading
- Self-Adaptive AI Models – Learns from new defect types and user feedback
- Enterprise Dashboard Integration – Monitor quality KPIs and defect trends across production batches
- Rejection Marking & Sorting – Automatically marks or diverts defective lenses
As demand for visual precision soars globally, the need for automated, scalable, and intelligent lens inspection systems has become paramount. Intelgic’s lens inspection solution delivers a powerful edge to manufacturers—combining AI, optics, and automation to detect what human inspectors can’t, while maintaining complete traceability and production analytics.
