High-end vacuum casted parts for Eaglet Eye

Eye Surface Profiler

The Eye Surface Profiler (ESP) is produced by Eaglet Eye. The ESP is a medical device that quickly scans the front surface of the eye and creates a highly detailed 3D map using advanced light projection and imaging.

the ESP measures the exact shape and height of the eye with very high precision, which helps eye care professionals design and fit customised contact lenses more accurately, faster, and with fewer adjustments, leading to better comfort and vision for patients.

Needless to say, the ESP is a high-end device whose parts and components have to meet strict requirements and specific standards. Like most many high-end devices, the ESP is produced in limited quantities, which often implies that conventional manufacturing technologies such as injection moulding are not suitable since there is no return on investments of tooling.

The same applies to the housing, which consists of two shells and is therefore manufactured through vacuum casting.

Vacuum casting

Vacuum casting is a method for producing high-quality plastic parts with properties comparable to injection-moulded components. The parts are casted using a silicone mould, which is created from a 3D-printed master. This master is typically produced using SLA (stereolithography), a process that provides a very smooth surface finish.

Each mould can be reused several times to replicate the same component. Casting materials are usually polyurethane resins that mimic the mechanical properties of commonly used plastics. Batches may vary between 10-20 parts per mold, depending on design and material.

Post-processing by Tenco

After casting, the parts are ready for a fit check to make sure they meet the right tolerances for assembly.

Next step is post-processing during which parts are spray-painted with a high-gloss finish, and the inner surfaces are coated with an EMC shielding layer. In addition, inserts and serial numbers are added to each part before quality inspection and final shipment.