Our coating process

I was hoping you could help identify anything we are missing or doing wrong.
Below I have written a comprehensive list of our current process. I would be more then grateful for any solicited comments or advice.

Thank you

Hard Coating:

1. Let's assume a clean lense enters the potassium hydroxide/ city water bath for 300 seconds @ 50°c including sonic.

2. 300s of city water @ 40°c

3. 300s DI water at 60°c with Sonic.

4. 300s drying (ceramic heating) @ 65°c

5. 300s cooling ( empty tray)

6. Primer ts-56 from tokuyama @ 11.2°c for 20s. ( Lacquer has been stored at -20°c for 19 months)

7. Stage 4. Then stage 5.

8. Lacquer ts-56 from tokuyama @ 11.2°c ( Primer has been stored at -20°c for 19 months)

9. Stage 4.

10. Out
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Oven (1 memment 110f oven)

1. From HC straight into Oven after check at 40°c holding temp

2. Degass batch at 60°c for 60 mins

3. Curing @ 115°c for 120 mins.

4. Hold at 40°c until ready for AR.
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AR

Recommend AR process from service provider.
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Results

1. Lens looks good after HC, spectrometer reads primer 0.7 and lacquer 2.9

2. After AR lens looks good but saltwater test gives a range of 4-2 score in salt water, shock , tape test.

3. AR coating is unstable, a very high percentage on lenses laminating completely in the following months.

Looking forward to tweaking this process into a great results.

Hello,
My coating process is the same...
I have same problem about AR coating which is unstable.
You find a solution ? thanks a lot

the first step is to visually determine whether the gap is between HC and lens or between HC and AR.
If HC also delaminates, try HC only lenses in boiling DI water for 15 and after 15 extra minutes. If you have delamination you must check the quality of the HC, if the Primer also comes off you must check the correct washing (if you do not rinse well after the soap you risk having a bad adhesion).
If you have delamination of the AR only, the first suggestion is to perform a Leak up rate to check the integrity of the vacuum (if you need, I'll explain the procedure but I need to know the type of system you have) the maximum allowable value must be less than 5 * 10-5 mb * l / s.
let me know if you need more information.
ciao
Mauro