It all starts with beautifully rich Mazzuchelli Acetate. The sheet of acetate is cut into rectangles about 15cm x 7cm. Small blocks of clear acetate are glued to the sheet using acetone - to be used for nose pads.
The rectangle of acetate is placed in the CNC machine at Morgana Optical, and the CNC mills the eye holes, lens grooves, nose pads, and the outer shape and edges of the front.
The temples are punched from the sheet of acetate.
A craftsman files and sands the surface and edges of the acetate fronts and temples. Holes are drilled into the front and temples for the hinge rivets that will be inserted later.
The fronts and temples are placed in tumblers for 12-18 hours to smooth and polish the surface.
The fronts are heated and then pressed on a mold to create the base curve. A machine called a “temple core shooter” heats the temple and shoots a metal temple core into the temple.
The hinges are made at Visottica Comotec in the same village where the frames are cut and assembled. The hinge is riveted by hand to the front of the frame.
The temple hinge is attached and screws tightened.
Our CR39 lenses are edged to the shape of the frame, and popped into place.
The frames are hand polished one last time by Paulo, and his team at Lupa Finitura Occhiali di Luciani Paolo, and sent to our headquarters in Flint, MI.