QUALITY CONTROL

(FINAL CHECKING)

AUTHOR
David Wilson: Brien Holden Vision Institute (BHVI), Sydney, Australia

PEER REVIEWER
Mo Jalie: Visiting Professor: University of Ulster, Varilux University in Paris

THIS CHAPTER WILL INCLUDE A REVIEW OF:

 Introduction
 Tools required for quality control
 Focimeter
 Lens verification by focimeter
 Power tolerances
 Bifocal segment – Size and alignment
 Lens verification using focimeter – Progressives
 Other instruments and tools
 Checking lens quality
 Checking lens frame alignment
 Lens measure
 Conclusion

INTRODUCTION

Before the completed spectacles are delivered to the patient, they need to undergo final checking. This quality control
procedure ensures that the spectacles meet the requirements of the prescription. The following criteria should be
checked against accepted tolerances:
 Power
 Centres
 Fitting heights
 Lens material
 Lens coatings
 Lens fit (and lens quality)
 Frame standard alignment.

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TOOLS REQUIRED FOR QUALITY CONTROL

After the spectacles have been produced, they need to be checked against the original prescription according to the
tolerances in the appropriate standards. Where national standards do not exist, the International Standards
Organisation (ISO) standard should be applied. In addition to the prescription parameters, the lenses should be
checked for defects and the frame put into standard alignment.

Figure 3.1: Quality control tools

The tools required for quality control are: (Figure 3.1):

1. The focimeter – to check power, locate optical centres and determine prismatic effect.
2. The lens measure – to check base curves and confirm the refractive index (R.I.)
3. Thickness callipers – to check that the lens meets the minimum thickness requirement.
4. A polariscope – to check for stress in glass lenses fitted to metal frames and to check for polarised lenses.
5. A light source – to check for surface defects (ideally the light source would be a fluorescent light at desk level).

FOCIMETER
The focimeter, also called a lensometer, lensmeter or a vertometer is the most important instrument in quality control
(Figure 3.2).

Its function is to measure the back or front vertex power of a lens or lens system as well as to determine the prismatic
effect, either ordered or unwanted.

Figure 3.2: The focimeter

For ophthalmic lenses, the back vertex power of the lens is measured when the back pole of the lens is resting on the
lens stop. Similarly, the front vertex power of the lens is measured when the front pole of the lens is resting on the lens
stop. The procedure followed has been outlined in the previous chapter.

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LENS VERIFICATION USING FOCIMETER

The use of the focimeter for checking completed spectacles requires a systematic approach. The following steps
should be carried out in all cases.

Step 1
Adjust the eyepiece to suit the observer. The
graticule should be clear and the power drum
should register as zero when the target is
focussed with no lens under test.
Step 2
Place the spectacles on the frame table and
adjust the height of the table until the target of
the right eye is centred.
Step 3
Check the power of the right lens and dot the
optical centre (Figure 3.3).
Step 4
SINGLE VISION Clamp the left lens and locate the target on the
Figure 3.3: Checking the power of the right lens
vertical meridian. Measure the lens power, the
amount of vertical prism and dot the lens. NB: If
the vertical meridian is stronger than the right
eye then adjust the frame table to locate the
optical centre of the left eye and return to the
right eye to determine the vertical prism.
Step 5
Remove the spectacles and measure the
centration distance as found by the dots on the
lens. Compare this measurement with the
ordered PD and determine the amount of
unwanted horizontal prism using Prentice’s
Rule.
Steps 1-5
The same as for single vision lenses.

Step 6
To check the power of the addition, place the
spectacles on the frame table with the convex
surface against the lens rest and measure the
front vertex power of the distance section of the
lens (Figure 3.4).

Step 7
Measure the front vertex power of the segment, Figure 3.4: Checking the power of
the difference between this measurement and the distance portion
BIFOCALS
the front vertex power of the distance is the
addition. Ensure that the same meridians in
used for both front vertex measurements
(Figure 3.5).

Figure 3.5: Checking the power of

the near addition

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POWER TOLERANCES

Note that Power tolerances are least for single vision and multifocals (bifocals and trifocals) and greatest for
progressive lenses. This recognises the complexity of progressive lens design and the relative simplicity of the
focimeter.

The following tolerances are used as a guide:

 From 0.09 D at  3.00 D to 0.37 D at > 20 D
 Tolerances on mean spherical power and cylindrical power
 Tolerances vary between single vision/multifocals and progressives

ADD TOLERANCES
 From 0.12 D at  4.00 D to 0.18 D at > 4.00 D

CYLINDER AXIS TOLERANCES

 From ±7° at < 0.50 D cylinder to ±1.25° at  0.50 D cylinder

DIFFERENTIAL PRISM TOLERANCES

 0.5 horizontal and 0.25 vertical for 5.00 D
 1.0 horizontal and 0.5 vertical for >5.00 D

PRISM DIRECTION TOLERANCES

 From ±5° at  3.00 D cyl to ±1. 5° at >6.00 D cyl
 Tolerance vary between single vision/multifocals and progressives

Note the more generous tolerances for higher powers. This recognises that accuracy is more difficult to achieve with
higher powers given that small movements when edging the lenses will lead to relatively high amounts of prism.

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BIFOCAL SEGMENT – SIZE AND ALIGNMENT

Segment diameter is measured at the widest point of the segment (Figure 3.6).

DIAMETER

Figure 3.6: Measurement of the segment diameter

Segment heights should be measured relative to the deepest part of the lens, that is, the
HEIGHT peak of the bevel at the deepest point on the lens shape. Alternatively they can be
measured relative to the horizontal centre line (HCL), previously known as datum.

Near centration distance should be measured from the geometric centre of the segment to
the centre of the bridge (monocular) or from geometric centre to geometric centre (binocular
near CD).

NEAR CD

Figure 3.7: PD measurement of a bifocal lens

Segment location for multifocals has a tolerance of  0.5 mm both vertically and horizontally
(each lens). Use PD ruler to read the distance between the distance optical centres and
between the segment geometric centres.
Confirm PDs with original order.

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LENS VERIFICATION USING FOCIMETER - PROGRESSIVES

STEP 1 Confirm the markings on the lens by finding the horizontal locator markings (Figure 3.8).
STEP 2 Adjust the eyepiece to suit the observer.
Place the spectacles on the frame table and adjust the height of the table until the distance
checking circle corresponds with the lens rest. Measure the lens power.

STEP 3

Figure 3.8: Reference points on a PAL

Move the frame table up until the prism reference point is in the centre of the lens rest
aperture and measure the prismatic effect at that point. There may be base down prism if
STEP 4
prism thinning has been applied by the laboratory. If this is the case merely note the
prismatic effect.
Clamp the left lens and adjust the height of the table until the distance checking circle
STEP 5
corresponds with the lens rest. Measure the lens power.
Move the frame table up until the prism reference point is in the centre of the lens rest
STEP 6 aperture and measure the prismatic effect at that point. Compare the prismatic effect with
that of the other eye to determine if there is unacceptable differential prism.
STEP 7 Check the monocular PDs and heights by measuring the location of the fitting crosses.
The addition for progressive lenses is permanently marked on the temporal side of the lens
directly under the horizontal locator. The addition, however, can also be checked using the
focimeter (Figure 3.9).

CHECKING THE
ADDITION FOR
PROGRESSIVE
LENSES Figure 3.9: Verification of PAL lens power using a focimeter

Step 1:
To check the power of the addition, place the spectacles on the frame table with the convex
surface against the lens rest and measure the front vertex power of the distance section of
the lens through the distance checking circle.

Step 2:
Measure the front vertex power through the near checking circle, the difference between this
measurement and the front vertex power of the distance is the addition. Ensure that the
same meridians in used for both front vertex measurements.

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LENS VERIFICATION USING FOCIMETER – PROGRESSIVES (cont.)

Figure 3.10: Lens verification using the focimeter

The target, when checking a progressive lens, may not appear as regular as a single vision
lens or bifocal. The reason for such irregularities in the image is the complexity of their
design and the relative simplicity of the focimeter. Focimeters were designed to measure
the power of lenses (front or back vertex) with light incident normally, along the principal axis
(Figure 3.10). Progressive lenses are designed using ray tracing and assuming a
pantoscopic tilt and positioning of the fitting cross at pupil centre with the patient in habitual
posture. As a result of the limitations of focimeters and their inability to read lens power in
the “as worn” position (with the exception of scanning focimeters), manufacturers have
incorporated what might be referred to as “windows of simplicity” into their designs. These
CHECKING THE
windows, the distance and near checking circles, are spherical in design and enable the
ADDITION FOR
practitioner to confirm that the lens has been made up correctly. If the fitting cross is
PROGRESSIVE
positioned directly in front of the centre of the lens rest aperture the image of the target
LENSES (cont.)
would appear distorted, as it does at the prism reference point. Some lenses, produced
using the “as worn” philosophy, alter the power at the checking circles and their ray tracing
programs produce an “equivalent power” for the focimeter to read.

Similarly, the combined effect of the aspheric surface of a progressive and an oblique
cylinder may result in the swinging of the axis at the near checking circle. This is
unavoidable, since the progressive surface is given in the design and the axis of the toroidal
surface is constant over the whole surface. It does not create problems for the wearer and
should be disregarded.

Checking the monocular PDs

Monocular PDs can be checked by laying the spectacles down on a layout card, most of
which have the facility to measure monocular PDs, or by using a parallel rule (Figure 3.11).

Figure 3.11: Checking monocular cards on a layout card

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LENS VERIFICATION USING FOCIMETER – PROGRESSIVES (cont.)

Alternatively, they can be checked with a PD rule.

At this point the positions of the near circles should be checked. It is possible that a right
lens may have been fitted instead of a left and vice versa. While this should be noticed when
checking the markings another check is worthwhile.

Checking the fitting cross height

Fitting cross height can also be checked by laying the spectacles down on a layout card
(Figure 3.12), most of which have the facility to measure both the heights and monocular
PDs, or by using a parallel rule.

Figure 3.12: Checking the fitting cross height using the layout card and a PD rule
CHECKING THE
ADDITION FOR Alternatively, they can be checked with a PD rule (Figure 3.13).
PROGRESSIVE
LENSES (cont.)

Figure 3.13: Checking the fitting cross height using a PD rule

Heights should be measured relative to the deepest part of the lens, that is, the peak of the
bevel at the deepest point on the lens shape. Alternatively they can be measured relative to
the horizontal centre line (HCL), previously known as datum.

The positioning of the fitting cross for progressive lenses have a tolerance of  0.5 mm, both
vertically as well as horizontally (each lens).

Prescription verification
Compare the original examination form or Rx with the job (not the order form). Occasionally
errors may be made in transcribing from one form to the other. By checking against the
original order we can eliminate the possibility of compounding errors.

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OTHER INSTRUMENTS AND TOOLS

Thickness callipers should be used to check that the centre thickness of minus lenses or the
THICKNESS
temporal edge thickness of plus lenses meets the minimum requirements. They would also be
CALLIPERS
vital for checking the parameters of iseikonic lenses.
The polariscope can be used to check for polarised lenses and for stress in glass lenses inserted
into metal frames. It is less useful for plastic lenses since the coatings of plastic lenses are
generally not homogeneous and so appear to show stress where none exists. Observation of the
POLARISCOPE
surface of plastic lenses is a better way of finding stress. A plastic lens under stress in the frame
warps and shows what appears to be “pinching” of the surface at the point of stress. The
polariscope will also identify glass lenses that have been thermally toughened.
A conveniently located light source, preferably at desk height, can be used to check for
scratches, pits, flakes on the edge of a lens, imperfections in the lens such as inclusions and
LIGHT SOURCE striae, and waves due to poor surfacing. The light source also serves as a useful tool for locating
the markings on progressive lenses, looking for gaps between the lens and the frame rim and
checking the quality of lens coatings.

An important part of quality

control is checking lens
quality. While the focimeter
will confirm correct power
it has only limited use in
checking for lens quality.
The focimeter will pick up
some imperfections, such
as waves, but will not find
scratches, inclusions,
striae etc.
OTHER
INSTRUMENTS
AND TOOLS

Figure 3.14: Checking lens quality

Lens quality check

requires observation of the
surfaces of the lens and an
image through the lens,
using a bright light source
(Figure 3.14). Lens
imperfections include
(Figure 3.15):

Figure 3.15: Various abnormalities in lens quality

This is a variation in the refractive index of the material, producing what appear to be fine
STRIAE scratches on the lens. On closer inspection and by using a pen to mark each surface adjacent to
the “scratches” it can be seen that the marks are inside the lens.
These are surfacing faults which create an irregular surface. This causes an image viewed
WAVES
through the lens to wobble as the lens is moved across the source (Figure 3.15).
Inclusions include bubbles, metal etc. These are the result of poor quality control in the
INCLUSIONS
manufacture of the plastic or glass material (Figure 3.15).

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OTHER INSTRUMENTS AND TOOLS (cont.)

The quality of the fit of the lens into the frame should also be checked
(Figure 3.16). It is particularly important with metal frames where excess stress
may cause lenses to chip or fracture.

OTHER INSTRUMENTS AND

TOOLS (cont.)

Figure 3.16: Checking lens frame alignment

The following should be checked:

 Air-gaps around the edges of the lenses (often referred to as “daylight”).
 Chips at the lens edge
 Uniformity of bevel
Stress in the fitted job (use cross-polarising filters to highlight) which appear as a
highlight dark shadow within the body of the lens with “hot spots” at the rim,
particularly at the eyewire position. These hot spots represent excess stress. Some
plastic lenses, however, may exhibit what appears to be stress where none exists.
This is due to the fact that the material or the coating may not be homogeneous. In
plastic lenses stress can be seen by inspection under a light source. The stress
appears as “pinching” in the edge of the bevel.

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LENS MEASURE

The lens measure should be used when checking spectacles to determine the base curve (of
bifocals and progressives) or the front curve of single vision lenses. For progressive lenses
the lens measure’s legs should be held horizontally over the centre of the distance checking
circle (Figure 3.17).

1. DETERMINING
BASE CURVE

Figure 3.17: Determining the base curve using a lens clock

The lens measure will only give an accurate measurement of the curves if the lens is made of
the same index as the lens measure’s design (usually 1.523 or 1.530). It will give a
reasonable approximation for CR-39 but the curve variation factor (CVF) should be applied to
other materials. For example, the CVF for high index glass of nd (neodymium) = 1.701 is
0.746. If a lens measure designed for nd = 1.523 measures the curve of a high index lens as
+10.00 D then multiplying the measured front curve by the CVF will give the true front curve
power.
That is, +10.00  0.746 = +7.46 D.
The lens measure can also be used to assist the practitioner to determine refractive index.
The approximate refractive index of minus lenses can be determined with reasonable
accuracy due to their minimal thickness. The procedure becomes less accurate with thicker
plus lenses.
nt = [ Ft (nm – 1)/ Fm ] + 1
Where: nt is the true refractive index of the materials (the “true” index)
nm is the refractive index for which the lens measure is designed (the “measured”
index)
2. DETERMINING
Ft is the power of the lens measured on the focimeter (the “true” power)
THE REFRACTIVE
Fm is the power measured by the lens measure
INDEX
For example, a lens which measures –10.00 D on the focimeter is found to have surface
curves of +4.00 D front curve and –11.50 D back curve when measured on a lens measure
designed for nd = 1.523. So:
nt = [ Ft (nm – 1)/ Fm ] + 1
nt = – 10.00 (1.523 – 1)/ – 7.50
nt = 1.698
While this will not provide an accurate measurement it will certainly allow the practitioner to
determine whether the lenses are of a higher than normal index.
Lens thickness should be checked during quality control, both for cosmesis and for safety.
Thickness requirements are:
3. DETERMINING Minimum “cut et” = 1mm
THE LENS If edge thickness (et) > 1 mm then lens is too thick and heavy
THICKNESS Errors results from inaccurate specification of frame dimensions
Minimum centre thickness (ct) = 1.5 – 2.0 mm for CR-39 (for manufacturing reasons).
Thickness can be measured with callipers or a thickness gauge.

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SUMMARY
Accurate refraction and dispensing demands equally accurate quality control of the finished spectacles.

The completed spectacles must be checked against internationally accepted standards.

Checking also requires a holistic approach, involving the checking of lens powers, lens and frame quality and standard
alignment.

BIBLIOGRAPHY
Jalie M. 2003. Ophthalmic Lenses and Dispensing. Butterworth Heinemann, London.
Jalie M. 1984. Principles of Ophthalmic Lenses, ABDO, London.
Wakefield KG and Bennet AG. 2000. Bennett' s Ophthalmic Prescription Work, Butterworth-Heinemann.
Brooks CW and Borish IM. 2006. System of Ophthalmic Dispensing. Butterworth Heinemann.
Brooks CW. 2005. Essentials of Ophthalmic Lens Finishing. Butterworth-Heinemann.
Wilson D. 2006. Practical Optical Dispensing 2nd Edition. Open Training and Education Network, Sydney.
Wilson D and Stenersen S. 2002. Practical Optical Workshop. Open Training and Education Network, Sydney.

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