Iterative design, a pipeline for development, and a future for connected eyewear

Ken McInerney, global engineering and technology product director at Transitions Optical, told OT that the first challenge in developing the new collection was to have all lenses fading back from activated to clear in under two minutes.

A second challenge was the creation of the ‘ruby’ colourway, as red is a notoriously difficult colour to create in photochromic lenses.

McInerney said: “To get ‘ruby’ under two minutes and at the right colour tone was a huge challenge.”

An additional hurdle was that all eight Gen S colours needed to fade-back true-to-tone. McInerney explained that different dyes are mixed-and-matched in ratios to create the different colours of the lenses.

Describing the process of fading back from activated to clear as a race, he shared: “Imagine three runners in a 100 metres race. One does it in 11 seconds, one does it in 15, and one in 80. In the formulation world, if I’ve got a green dye, a blue dye, and a brown dye, and the green dye is the slowest, when it is fading back you are going to get a green or a purple hue.”

This creates a shift towards a purple or a green tint as the lens fades back to clear.

“What I needed to do was get all the dyes developed at the same kinetic so everybody is running the race in 12 or 14 seconds so when it fades back, irrespective of the combination of dyes, they are all fading back at the same speed. That’s the magic,” McInerney continued.

He added: “Gen S has no compromises. It fades back all the way with all eight colours. It was a real feat of science, chemistry, and research coming together.”

Pushing boundaries

What does the pipeline look like for development at Transitions? McInerney described a funnel with a wide mouth to collect ideas that narrows down to focus on a select few projects to take forward.

He said: “I’m a big believer in creating a culture where people are allowed to fail and are recognised, because it means you are pushing the boundaries and that is the mindset we want. The diversity of thought, profile, and mindset, creates a rich melting pot of ideas.”

Transitions’ latest development, the Color Touch line of gradient and tinted lenses, took about six months from concept to presenting prototypes at the 2024 Transitions Academy. The new lenses will arrive in the UK in 2026.

McInerney described the development of the new collection as an iterative process between a “technology push and a market pull,” taking consumer insight into account.

He continued: “We knew we wanted it to be an everyday lens that could be used for night and day. Then it was a question of coming up with the colours and different prototypes.”

The creation of the Color Touch gradient and wash lenses required a fine balance.

“You want to have a hint of colour, and you don’t want it too activated, but equally, not too faint,” he said.

A computational modelling system was used to provide a starting point from which to build upon when designing the Transitions lenses to meet particular attributes, such as speed of fade-back and colour tone.

Smart eyewear

Reflecting on the journey of Transitions and the roadmap ahead, McInerney shared that the business was initially built around two axes: visual comfort and protection. This expanded to include ‘style’ following the launch of Gen S.

“Now the fourth leg of the stool is going to be visual help,” he said, adding: “There is a very exciting period ahead of us in the next two to three years.”

Photochromic lenses have a role to play in the future of connected eyewear. The Transitions Academy stage shone a spotlight on Nuance Audio; glasses designed with an invisible, incorporated hearing solution for individuals with mild to moderate hearing loss.

Highlighting the benefit of Transitions lenses with smart eyewear, McInerney said: “If you have a hearing condition and you are using Nuance Audio – you don’t just have a hearing condition indoors. Transitions lenses in those frames is a technology enabler. The same can be said for RayBan Meta.”

As the knowledge base increases, so does the ability to push the envelope of chemistry to target certain wavelengths and achieve particular functionalities, McInerney said.

“Added functionalities are going to allow us to revolutionise eyewear in the future,” he said.

McInerney continued: “Photochromics will be an enabler in moving into that space of visual health and health and wellness. I think Gen S was the first product that has broken that ceiling. We’re able to prove through double-blind, randomised trials, that we are able to improve visual health. I think we are going to build on that significantly in the coming years.”