Abstract: The present invention provides a method for preparing a customized polymeric article including: providing two mold half-sections, each half-section having an outer surface and an inner surface; assembling the two mold half-sections to form a mold assembly such that the inner surfaces define a cavity there between; applying one or more magnetic fluids to the inner surface of a mold half-section; inserting a fluid polymeric material into the cavity; controllably applying a magnetic field to the magnetic fluids to form a customized reversible surface in accordance with a predetermined specific surface topography; subjecting the mold assembly to conditions sufficient to effect polymerization or hardening of the fluid polymeric material; and separating the two mold half-sections. Articles prepared by the method also are provided.

Abstract: A batch process for preparing a molded optical article includes introducing (i) a dithiol component or (ii) a polyisocyanate component into a reaction vessel; adding a first catalyst of organotin halide to form a first reaction mixture; heating the first reaction mixture; introducing a second catalyst of tertiary amine to the first reaction mixture; mixing a polyisocyanate (ii) into the reaction vessel containing the first reaction mixture if dithiol (i) was first added, or mixing a dithiol (i) into the first reaction mixture if the polyisocyanate (ii) was first added, to form a second reaction mixture; filling a mold with the second reaction mixture to provide a filled mold to form a molded optical article. The molar ratio of elemental tin present in the first catalyst to tertiary amine compound present in the second catalyst ranges from 0.04:1 to 0.29:1.

Abstract: The present invention provides a method for preparing a customized polymeric article including: providing two mold half-sections, each half-section having an outer surface and an inner surface; assembling the two mold half-sections to form a mold assembly such that the inner surfaces define a cavity there between; applying one or more magnetic fluids to the inner surface of a mold half-section; inserting a fluid polymeric material into the cavity; controllably applying a magnetic field to the magnetic fluids to form a customized reversible surface in accordance with a predetermined specific surface topography; subjecting the mold assembly to conditions sufficient to effect polymerization or hardening of the fluid polymeric material; and separating the two mold half-sections. Articles prepared by the method also are provided.

Abstract: Provided is a process for preparing a molded optical article that is essentially free of optical defects. The process comprises: a) introducing each of two separate reactive components A and B from separate supply vessels into a mixing chamber having a volume of 200 ml to 2000 ml; b) mixing the components together in the mixing chamber for a period of 50 to 200 seconds to form a reaction mixture; c) injecting the reaction mixture at a temperature of up to 130° C. into a mold; d) holding the reaction mixture in the mold at a temperature and for a time sufficient to essentially cure the reaction mixture and form a molded optical article; and e) releasing the article from the mold. The process is particularly suitable for preparing polythiourethane lenses with high yield, high transparency, very low haze, low flow lines and low inclusions.