Case Study: Earlens Corporation achieves micron-level mold accuracy and 10x faster production with Carbon’s OTA-enabled M Series printers

Earlens Coportation - Customer Case Study

Earlens Coportation, maker of a light-driven hearing aid that requires anatomically precise lenses, faced slow, hardware-sensitive production of custom lens molds—traditional SLA took three to six hours per set and required machine tuning that impacted other parts and reduced equipment utilization. To overcome these speed and tunability challenges, Earlens turned to Carbon, using Carbon’s M Series printers and its over-the-air (OTA) software update capabilities.

Carbon delivered a software-based optimization (no hardware changes) on the M Series printer using PR 25 resin and Digital Light Synthesis™, cutting mold print time to about 45 minutes (~10x faster) and improving accuracy to 90% of points within ±30 microns (from ~±45 microns initially). The Carbon solution eliminated downtime for machine reconfiguration, preserved the printer’s ability to run other materials, and enabled Earlens Coportation to produce anatomically accurate lens molds at production speeds and specifications.

Earlens Coportation

Mark Bishop

Vice President Operations