Abstract: The disclosed embodiments include a system, apparatus and method for forming an ophthalmic lens having reduced risk of optical defects. An illustrative injection molding system includes a heated sprue and a hot runner fluidly coupled to the heated sprue. The system also includes a mold fluidly coupled to the heated runner to receive a molten material. The mold includes a material conduit, which may be included in an interchangeable gate insert, and a lens cavity. The hot runner forms a material conduit having an inlet for receiving material from the hot runner and an outlet for delivering material to the lens cavity. The material conduit also includes a branch cavity disposed between the inlet and the outlet for receiving a diverted volume of degraded lens material.

Abstract: The disclosed embodiments include a system, apparatus and method for forming an ophthalmic lens having reduced risk of optical defects. An illustrative injection molding system includes a heated sprue and a hot runner fluidly coupled to the heated sprue. The system also includes a mold fluidly coupled to the heated runner to receive a molten material. The mold includes a material conduit, which may be included in an interchangeable gate insert, and a lens cavity. The hot runner forms a material conduit having an inlet for receiving material from the hot runner and an outlet for delivering material to the lens cavity. The material conduit also includes a branch cavity disposed between the inlet and the outlet for receiving a diverted volume of degraded lens material.