The Power of Simulation in Lens Design and Fitting

March 2025 - Go to Designing page

Innovation is often driven by the ability to test and refine ideas before they become reality. Yet, the role of simulation in shaping technological advancements is frequently overlooked. We tend to associate history’s greatest technological breakthroughs with hands-on experimentation, engineers building prototypes, or doctors testing treatments. But behind many of these advancements, simulation tools have played a silent yet transformative role. The same principle applies to contact lens design and fitting. Since our beginnings in 1994, we have understood that precise simulation is not just a helpful tool, it is essential to achieving the best results for both designers and patients.

How Simulation Has Transformed Industries

Before digital simulations, engineers relied solely on physical testing to improve aircraft performance. One of the most revolutionary tools in aviation history was the wind tunnel, which allowed researchers to study airflow around aircraft models. During World War II, wind tunnel testing helped the British optimize their fighter planes, leading to innovations like retractable landing gear, which dramatically reduced drag and improved speed. This was an early example of how controlled simulations provided critical insights before implementation, shaping the future of aerodynamics.

Another groundbreaking development was NASA’s digital twin concept, pioneered in the 1960s. A digital twin is a virtual replica of a physical object, allowing real-time monitoring and testing without direct intervention. This technology became a lifesaver during the Apollo 13 mission, when an oxygen tank explosion endangered the astronauts. NASA engineers used ground-based simulations to test solutions in real-time, ultimately devising a workaround that brought the crew home safely. In so many industries simulation didn’t just change how we build, it changed how we learn, innovate, and push boundaries.

Simulation in FocalPoints Designer

We bring this same mindset to the world of specialty contact lenses. Historically, lens design was an expensive and time-consuming process. To test a new design, lens makers had to cut physical samples, evaluate the geometry, and adjust accordingly, approach that was not only slow but also led to significant material waste. With FocalPoints, we have changed that paradigm. Our software allows designers to simulate and test multiple iterations virtually, refining geometries before they ever reach production.

Optical Profiles Simulation, analyzes lens power and optical properties before production
Power Map Simulations, details of how the lens interacts with tear layer and cornea
Lathe Tool Simulation, predicts how the cutting tool interacts with the lens surface
Dynamic Analysis, assesses whether complex designs can be produced efficiently

Simulation in the Lens Fitting Process

Simulation doesn’t just enhance design, it also plays a crucial role in lens fitting. Every patient’s eye is unique, and achieving a perfect fit requires precision. That’s why FocalPoints includes advanced fluorescein pattern simulations, allowing practitioners to analyze how a lens will sit on the eye before a patient ever tries it on.

Fine-tuning lens parameters based on real corneal topography
Virtual evaluation of tear film behavior, for comfort and stability
Customization of edge profiles and vaulting

By using these simulations, eye care professionals can eliminate unnecessary trial-and-error, significantly reduce patient chair time, and ultimately improve visual comfort and performance.

A Future Powered by Simulation

Simulation has played a defining role in aerospace, engineering, and manufacturing, and now, it is revolutionizing contact lens design and fitting. We believe that precision and innovation should go hand in hand. With FocalPoints, we are not just improving lens designs, we are constantly pushing the boundaries of what’s possible in specialty contact lenses. Whether you’re a designer striving for perfection or an eye care professional seeking the best patient outcomes, simulation is your most powerful ally.

From the very start, FocalPoints wasn’t just designed to solve existing challenges, it was built to provide the best possible technical solution for contact lens designers. Thanks to our visionary founder, Renato Liffredo, we pioneered groundbreaking features decades ahead of the industry. Today, we continue this legacy, pushing the boundaries of imagination and technology.
Filippo Selden, CEO Advance