Surface chemical structure for soft contact lenses as a function of polymer processing

The surface chemistry and topography of cast‐molded Etafilcon‐A and doubled‐sided lathed Etafilcon‐A soft contact lenses were determined to be significantly different. The variations in surface chemical and morphologic structure between the two lenses were the result of contact lens manufacturing methods. The surface of the cast‐molded Etafilcon‐A had a consistently less rough surface compared to the doubled sided lathed Etafilcon‐A as determined by atomic force microscopy. The surface of the doubled sided lathed Etafilcon‐A contained primarily silicone and wax contamination in addition to minute amounts of HEMA. The cast‐molded Etafilcon‐A had an elemental and chemical content which was consistent with the polymer stoichiometry. Contact angle wettability profiles revealed inherent wettability differences between the two lenses types. The cast‐molded Etafilcon‐A had an inherently greater water wettability, polarity, and critical surface tension. This means that these two lenses cannot be compared as similar or identical lens materials in terms of surface composition. The manufacturing method used to produce a soft contact lens directly determines the surface elemental and chemical structure as well as the morphology of the finished lens material. These results suggest possible differences in the clinical comfort, spoilage, and lubricity felt during patient wear. © 1996 John Wiley & Sons, Inc.