How to Reduce Remakes: The Top 7 Avoidable Errors in Lens Ordering

By Jon J. Trutt

Published: 11/25/2025

Remakes are the silent profit killers of every optical practice. They drain time, eat up margins, frustrate patients, and put unnecessary strain on your team. The good news? Most remakes aren’t caused by the lab. They come from small, preventable issues that happen before the job ever hits the tracer.

At AccuLab, we see thousands of jobs come through every month, and we’ve learned exactly which mistakes cause the most headaches—and how easily they can be avoided. Here are the top seven errors that lead to remakes, and what your team can do to cut them down dramatically.

1. Incorrect Measurements (PD, Seg Height, OC Height)

Let’s start with the big one: measurements matter more than anything.

A PD that’s off by even 1–2 mm, or a seg height that isn’t captured from the patient’s natural posture, can create visual discomfort, swim, or unwanted prism. Progressive lenses are especially unforgiving—precision is everything.

How to avoid this:

• Take monocular PDs whenever possible.

• Ensure the patient is standing or seated naturally during height measurements.

• Double-check heights on tall frames or deeper B measurements (common source of error).

• Use a digital measuring device as a backup, not the only method: human confirmation is key.

2. Choosing the Wrong Frame for the Prescription

This one doesn't get talked about enough. The truth is: not every frame works for every prescription.

High minus lenses in oversized fashion frames? Thick edges and unhappy patients.

High plus lenses in tiny, narrow frames? Instant distortion issues.

Progressive lenses in frames with too little vertical depth? No usable reading area.

How to avoid this:

• Guide patients toward frame shapes that support their Rx—don’t just let them pick based on style alone.

• For progressives, look for at least 28–30 mm of vertical depth whenever possible.

• For higher minus, choose smaller, rounder shapes to keep edge thickness down.

• For higher plus, avoid narrow rectangles; opt for more symmetric shapes.

The right frame choice can eliminate a huge portion of remakes before they ever start.

3. Inaccurate or Misunderstood Lens Material Selection

Sometimes the patient is fine—it's the material that isn’t.

Polycarbonate may be great for thinner, stronger lenses, but it’s not ideal for every prescription.

1.67 or 1.74 may give the thinnest look, but at the cost of Abbe value and potential visual clarity. We suggest always adding anti-reflective coating to combat this.

How to avoid this:

• Use higher-index only when it makes sense for the Rx.

• Don’t forget Trivex and 1.60. These are fantastic options for clarity and safety.

Correct material = better vision + fewer remakes.

4. Wrong Base Curve or Poor Frame Wrap Handling

As wrap frames grow in popularity, so do remake issues related to base curve and frame angle.

Watch out for:

• Ordering standard lenses for a frame with heavy wrap.

• Ignoring face-form angle and pantoscopic tilt during measurements.

A mismatch here can cause peripheral blur and “fishbowl” effects that patients often blame on the lenses.

5. Incorrect Segment Style or Design for the Patient’s Lifestyle

Even when measurements are perfect, the wrong lens design can cause an easy remake.

Common pitfalls:

• Using a standard progressive on someone who stares at screens 8+ hours a day.

• Choosing a short corridor when the frame depth allows for a standard corridor.

• Giving a flat-top to a patient who needs more intermediate than near.

Tip:

Ask more lifestyle questions than Rx questions. The right design solves problems before the patient ever experiences them.

6. Missing or Incorrect Frame Measurements (A, B, DBL, ED)

Sending the wrong frame measurements can result in wrong blank size selection and unnecessary delays or remakes.

Avoid this by:

• Always tracing the frame when possible.

• If sending measurements manually, verify A, B, ED, and DBL twice.

• For rimless: ensure accurate drilling coordinates or supply the existing lens if duplicating.

7. Not Confirming Details with the Patient Before Ordering

This is one of the simplest fixes, but it’s also one of the most overlooked.

Confirm with the patient:

• Tint color & darkness

• Polarized vs. non-polarized

• AR coating choice

• Add power

• Desired lens features (blue light, Transitions®, etc.)

A 10-second confirmation step can save a 10-day remake cycle.

Final Thoughts: Remakes Are Preventable with the Right Process

Your patients trust you to deliver precise, comfortable, and clear vision. With careful measurements, smart frame selection, thoughtful lens design choices, and strong communication, you can dramatically slash your remake percentage.

At AccuLab, we’re always here to help, from verifying tricky Rxs to recommending the right design or material. The more we work together, the fewer remakes you’ll see on your schedule. Remember: A great optician knows when to say 'No', and always explains why!

· Contact us: 800-688-3904 or info@acculab.net