The Art of Manufacturing Horn Glasses

The manufacturing of horn glasses is a perfect combination of traditional handicrafts and modern precision processing. The manufacturing of horn glasses does integrate traditional handicrafts and modern precision processing technology. This process not only retains the essence of traditional craftsmanship, but also improves the precision and quality of the products with the help of modern technology. 

Choosing the Right Material

To create high-quality horn frame glasses, the first step is selecting the right horn material. Adult buffalo horns, primarily sourced from regions in Asia and Africa—such as Tibet, India, and parts of Africa—are ideal. These horns are valued for their density, aesthetic appeal, and toughness. When selecting horns, it's crucial to discard those with cracks, insect damage, calcification, or internal cavities to ensure uniformity in color and texture. High-quality horns are essential for producing exceptional horn glasses.

Pre-Treatment of Horns

Once the horns are selected, they undergo pre-treatment. Soaking them in a food-grade hydrogen peroxide or sodium hypochlorite solution (3%-5%) for 24 hours serves to sterilize and preserve the material. Subsequently, the horns are steamed at 80-90°C for 2-3 hours to facilitate cutting.

Cutting and Shaping

The pre-treated horns are then cut using a band saw or CNC cutting machine, ensuring the preservation of the natural texture direction. It’s important to control thickness during this process, with pieces cut to a thickness of 3-8mm, depending on whether they are for the frame or temples.

Pressing and Grinding

The cut horn pieces are placed in a constant temperature press and heated to 120-140°C, where they are pressed at 10-15MPa for 30 minutes to form a flat plate and eliminate any natural curvature. The plates are then ground using double-sided abrasives in two stages:

1. Rough Grinding: Using an 80-120 mesh belt sander to remove burrs and achieve a thickness tolerance of ±0.2mm.
2. Fine Grinding: Manual grinding with 400-600 mesh sandpaper to eliminate scratches, achieving a surface roughness of Ra ≤ 0.8μm.

Inspectors meticulously check each horn plate for defects, ensuring that only flawless materials are used for production.

Producing the Front Frame

The front frame of the horn glasses is crafted using CNC technology.

1. CNC Finishing: The inner and outer rings are refined with a carbide milling cutter, ensuring precision in lens groove depth and outer design outlines based on CAD specifications.
2. Nose Pads: These can be made from horn or metal. Horn pads are adhered using epoxy resin and cured, while metal pads are embedded into pre-cut grooves in the frame.

Polishing and Bending

After shaping, the surface is polished using ceramic triangle blocks and walnut shell particles to achieve a smoother finish. The hot bending process involves local heating and shaping using infrared or hot oil methods, ensuring ergonomic design.

Hinge Assembly and Final Touches

The hinge assembly requires high precision, using tungsten steel drill bits for drilling. Medical-grade stainless steel is typically employed for hinges, ensuring durability through thousands of uses.

Temple Production

Temple shaping follows a similar CNC process, with careful attention to design and curvature. Hinge and polishing processes mirror those used for the front frame, focusing on balance to prevent slippage when worn.

Final Assembly and Quality Control

The final assembly involves data input for CNC lathes, laser engraving for branding, and the secure installation of metal accessories. Each pair is packaged according to customer specifications, typically in eco-friendly materials.

Innovations and Challenges

Anti-Crack Treatment

To prevent deformation or cracking due to humidity, finished horn glasses are coated with BABY oil.

Texture Matching

Because horn is a natural material, matching colors and textures from different sources is vital for aesthetic consistency.

Environmental Responsibility

Recycling horn scraps into buttons or crafts promotes sustainability and reduces waste.

Each pair of horn glasses requires over 200 meticulous processes and takes 20 to 30 days to complete. High-end horn glasses not only protect your eyes but also serve as handcrafted collectibles. The manufacture of horn glasses exemplifies the perfect blend of traditional artistry and modern precision engineering.