TD Tom Davies Factory Tour - Part 4

Next was the Shocking bath. This isn’t what you think! There are no unscrupulous hygiene practices afoot at the TD Factory. This was a vat of oil, maintained at a specific temperature, to enable the setting of any adjustments made to buffalo horn frames. Originally when Tom was experimenting with horn frame production he had used an old ice-cream freezer for this. Want not, waste not!

Adjacent to the “shocking freezer” was an almost “steam-punk” looking pneumatic ram. This was the temple-shooting machine. This fired the strengthening core, which for all TD Tom Davies frames is high grade titanium, into the acetate temples. On the same desk was the silver solder apparatus and titanium pulse welder.

Behind this row of equipment, the underneath of the mezzanine is efficiently used. No part of the factory is free from Tom’s innovation and this area is no exception. Housed here, the tumbling and polishing drums. In mainstream spectacle frame production, the pieces of each frame are tumbled in large drums, often filled with bamboo pellets.

Due to the individual nature of the TD Tom Davies eyewear, this just wasn’t up to Tom’s exacting standards. He has both varied the sizing of these drums to enable individual and multiple frames to be tumbled efficiently, but also uses different types of wooden pellets to achieve different levels of desired finish. Tom doesn’t believe in “one size fits all!”

Adjacent to the tumbling is the “elves grotto!” Here the state-of-the-art laser engraving is conducted and stock ready to be shipped is housed. Tom was excited to say they have in excess of one million UK pounds (C$1.7million) of ready-to-wear frames ready for customers drastically reducing wait times and improving shipping efficiencies.

Part 3 ... /
Part 5 ... /

By Dr. John Wilson

TD Tom Davies Factory Tour - Part 3

The polishing machine consisted of two industrial polishing wheels, controlled by way of a foot pedal allowing the operator safe use of both hands, and numerous different grades of polish blocks. Too harsh a polish at the wrong stage would spoil the final result. Alternatively, too fine a polish, too early in the process, would lengthen the time taken to achieve the end result, thus rendering the final completed frames more expensive to manufacture.

Perpendicular to the polishing station was the hand sand-blaster. This resembled a piece of lab equipment from the film “Outbreak.” A transparent fronted box with two entrance holes attached to thick, rubberized, internal, self-contained gloves used to hold the apparatus being treated (sand-blasted). Tom explained that doing this by hand required proper training, but well worth it, as the finish achieved was far superior to a mass-produced product.

Behind us was a couple of work benches where an experienced spectacle maker was hand-finishing the ready-to-wear frames ensuring all edges and joints where “square” and smooth when running your finger across it. “It’s what all Opticians expect when they’re selecting their frame stock. The better the joint, the better the finished spectacles.”

Around the corner to the next set of benches was the lug insertion machine. Tom had pioneered the use of a low melting-point metal alloy to cast a die to hold the frame front in the correct position in order to heat-sink the lug into the acetate front of the spectacles if not riveted. The alloy die could be produced in minutes, unlike the previous method of machining the die. This again allowed more cost-effective production of bespoke frames. Tom was proud to say that this method has been adopted by most of the spectacle industry.

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Part 4 ... /

By Dr. John Wilson

TD Tom Davies Factory Tour - Part 2

First point of call was a large expanse of shelves with adjacent machinery. These shelves contained the banks of acetate material in varying sizes for the spectacle frame fronts and temples. Tom explained how each acetate sheet has a natural curve which dictates the front and rear of the material. “If you go against the curve that frame will continually loosen as it ages” Tom explained. “So if you’ve ever wondered why your sample colours can only be used one way, this is the reason.”

Next to Tom was a large industrial jigsaw to cut the plates into usable sizes and a shaper machine to reduce the thickness of the plates for various designs. Behind him stood a large industrial looking, stainless steel box fronted by a hefty looking steel door. This was his acetate oven. Once the acetate had been stored for a period it was then pre-aged to reduce shrinkage. Excess water was removed from the acetate so that once crafted into the final spectacle frame it maintained it’s design as closely as possible. Tom expressed that when this care is taken the finished eyewear is much improved in its quality and requires less adjustment after dispensing by the Optician. “It’s part of the reason you pay for quality over quantity. “Tom continued.

Next on the agenda was a high rendered wall with a rather solid, heavy looking locked door. We all waited patiently as Tom revealed this was his champagne tasting experience. The door opened with a small muted fanfare and we all eagerly edged forward to discover a large empty store room. Tom elaborated that the room would be filled with stock once the factory was running at full capacity, hence the champagne experience, and we were getting a taste of what was to come.

Our next introduction was to what Tom referred to “as our first real machine on the tour.” This was “TD Bespokeanator 6.” A very sophisticated one of a kind, custom-made, programmable CNC machine. Unlike other CNC spectacle machines, this one had Toms magic bestowed on it. It has enhanced programming and Tom has “bespoked” the tool to his own design.

This enables its tools to be changed efficiently and programming altered frequently to produce bespoke, one-of-a-kind product with a minimum of down time. “This enables a much more affordable bespoke experience for our customers.” Tom enthused. Side by side with “Bespokeanator 6” was a second CNC machine set up to produce the “ready-to-wear” frame fronts. These would produce Tom’s stock supplies and would run with only the change in colour palette required after each set up.

Throughout the tour Tom emphasized his ambition to grow the talent in his business introducing us to his three new apprentices. One of these, John, had started just three days earlier and his first job was learning how to hand-polish the spectacle frames. John elaborated that it was expected to take a minimum of three months of training before Tom was confident an apprentice was competent at hand-polishing to his exacting standards.

Part 1 ... /

Part 3 ... /

By Dr. John Wilson

TD Tom Davies Factory Tour - Part 1

We were over in London, UK, in January, visiting our homeland for 100% Optical. Dr. Euan and myself (Dr. John) had been invited to give a lecture on our experiences of practicing optometry in Canada and the UK. Whilst over the pond Tom Davies of TD Tom Davies invited us to visit his new Bespoke London factory. Well this was an opportunity not to be missed!

It was Friday afternoon when we jumped in a “Black Cab” to head to the factory which is close to Heathrow Airport. Talk about interesting. London Cabbies know something about everything and our Cabbie was no exception. Suffice to say we put the world to rights.

Before we knew it, we pulled up at some large white industrial units surrounded by tall black railings. There were numerous damaged Mercedes cars in the parking lot (we later found out that this was the storage compound for the Mercedes repair centre) to our left, but we needed to find number 1. The security guard directed us to the right and told us we needed to be at the other end of the building.

Up the final steps we went, only an hour early, and pressed the buzzer for the intercom. “Euan and John from Ocean. We’re early.” Our reply was prompt and welcoming, “No worries, I’ll be right down.” The chap that met us was tall, slim and stylish. He showed us through what seemed a maze of corridors past rooms with names like “The Lego Room” and the “Staff room of tranquillity,” then up some black, rugged and industrial looking steps onto the mezzanine.

Immediately in front of us there were doors to the factory offices and two retro arcade machines. One had an impressive array of 80’s video games and the other being an original Star Wars slot machine. Adjacent to these an impressively stocked black coloured, mirrored bar complete with a couple of draft ales on tap and fancy bar stools. On the bar was a huge Bluetooth speaker and “bean to cup” coffee machine.

To the right of the bar was the staff area. This consisted of numerous fitted kitchen units, microwave, large side-by-side refrigerator, central prep island with large chef’s oven and three large tables and associated chairs. At the furthest of these was Tom, Allister and another man engaged in a meeting. To the left of us where the toys. Large air-hockey table covered with a huge artists canvas, a bar football game, another arcade game and a full-size, two-person Sega Rallye game, the ultimate console arcade game IMHO.

At this point we were introduced to some of the staff, graphic designers, sales and admin support. As we were early it was suggested that we should sample a few drinks at the bar and practice on the Sega Rallye game, well it would be rude not too! After only a short period we got our recognisable, robust welcoming from Tom.

For anyone who’s never see or met Tom, he’s a decent sized chap, probably 6’ 2’’, with an athletic to heavy build, strawberry blonde, short cropped hair and sporting a reasonable amount of designer stubble. His greeting is becoming of his stature but often involves a hug and this was no exception. He’s a very warm, welcoming and giving man whom we are honoured to call a friend. Immediately Tom challenged Euan to the Sega Rally game. This was too much fun not to post live on FaceBook but unfortunately Tom was well practiced, and Euan was beaten!!!! (Only just if you ask Euan.)

After just a short wait we were joined by Dr. Michael Johnson from Johnson & Furze Opotmetrists, another Independent Optometrist and fellow TD Tom Davies stockist. Now the tour was ready to begin!

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TD Tom Davies Factory Tour - Part 5

We were then led along a narrow corridor beside the elves grotto to what can only be called “the staff enrichment region” of the factory.

Through the first door we were treated to a room full of Lego. Not just bright coloured bricks, although there was a huge number of these, but multiple specialized models from airports to zoo’s. My favourite was the Millennium Falcon and Star Wars collection, which, if you follow us on Social Media will be no surprise, as that morning both Euan and I had attended a fully immersive VR Star Wars game in a nearby shopping mall. Euan had worn his Rebel Alliance Tee shirt especially. Really, he did!!!!!

The next door was the Room of Tranquillity. As we entered it was dimly lit with LED mood lighting.  There was a small atomiser emitting calming scent and towards the back a large, rather comfortable -looking, very padded chair. Tom announced his attendance into the room which brought the chair to life via a Google Alexa device. Once in the chair you can select your desired massage through voice activation. Very cool, and relaxing.

These two rooms were to both challenge and relax staff through the day to improve their creativity and mood.

As the work day was coming to a close Tom invited us to stay for a spot of dinner and a drink before returning to our hotel ready for our Independent Optometry Conference the following day. Little did we know that the tour was not yet over. We were then shown up to the roof.

The entirety of the factory roof had been turned into a roof-top patio area, fully equipped with a fully functioning bar, a BBQ that Tom’s good friend Heston Blumenthal had presented him as a gift on the opening of the factory, which was massive, a raised performance area for invited bands/musicians to play and a life-size ceramic, multicoloured Zebra. Everyone needs a multicoloured Zebra, don’t they?

Dusk had fallen but this being London, the street and building lights filled the night sky with an ambient glow that only a large conurbation can. In the distance were planes taking off and landing at Heathrow Airport but with the music playing you could easily have imagined being in a trendy Mediterranean bar, that is, if there wasn’t a frigid breeze reminding you that, “this, my friend, is London in January and don’t you forget it!”

Part 4 ... /

By Dr. John Wilson

New York / Vision East Expo Day 3

The day started bright and clear, but cold.  We shouldn't really complain, though, as we'd escaped the snow storm which had battered Nova Scotia over the last 24 hours so we were fortunate to be in New York.

This day was going to be a very special day - TD Tom Davies's Creative Lab.  We were invited to spend a whole day with Tom and his team to have further training in the creation, design and modification of spectacle frames.  We have carried the TD Tom Davies range since we opened and already felt very comfortable and confident with our abilities to bespoke the measurements for specific requirements and create unique colour combinations as one-off eyeglasses for our patients.  It is always good, however, to refresh our knowledge and we wondered what else the day would bring.

A short stroll from our hotel brought us to the very cool Ink 48 hotel, one of New York's fine boutique hotels.  In we went and straight up the elevator to the penthouse floor.  While this may seem lavish, the cost was a fraction compared to exhibiting at the main show and many of the frame companies we work with choose this option as it helps protect their concepts and designs from the prying eyes of those who would simply wish to copy them.

The Creative Lab awaits

As we come out of the elevator, at the end of the corridor an open door and sign beckons - this is kind of exciting, I have to say!

Wow!  We walk in to the suite and are greeted with 180° views of the Manhattan skyline and out over the Hudson River.  We meet with Tom and Nathan, it's great to quickly catch up with them since we last met in Paris.  While we chat regularly by phone and e-mail, there's nothing better than meeting face to face to really catch up.

One of the limited edition pieces

To start the day we review the collection of frames that Tom has with him.  This represents not only his full collection, but also some limited edition pieces and also some prototypes which are current works in progress. 

We were looking to choose five or more frames that we liked or inspired us to then work on.  This particular blue on blue titanium/acetate limited edition model definitely caught my eye.

Lots of choices

With the pieces chosen, the next thing was to download all of the CAD files from Tom's database.  With the CAD printed off we were then set to work.  Tom gave an introduction to designing and modifying frames from the drawings.

This is a very different experience to modifying a frame for a particular patient, here you are given a complete free reign - you can change a thickness here, an angle there, even modify the position of different components on the frame.  Whatever you can imagine can be achieved, of course, whether it will work or not is another matter!

CAD with modifications

It's almost overwhelming to begin with.  Perhaps inside every eye geek is an inner feeling that they could be an eyewear designer.  Now we were having a chance to try our hands at it, it's almost like being a kid in a candy store and being told you can pick anything ... everything!  Where to start!?

With a few swoops of a pencil, though, we started to get in to a groove.  I like how the frame is here, but I'd change the frame there.  I like the bridge from this frame, so I'll use it on that one.  All the time Tom, Nathan and Josh were coming around; checking how we were getting on, making gentle suggestions; explaining what would and wouldn't work.  We also started comparing each other's designs and it is amazing the variety of different options that you can come up with you start to look at this.

The setting was inspirational as well, with so many beautiful frames laid on every available surface we were never short of different designs to look at.  Even gazing around the skyline, though, you start to notice different elements from the architecture around and the colours of the city.  Could they be incorporated?  Why not.

When we were happy, Tom would review each individual design and if it was acceptable, it was photographed for e-mailing to his CAD designers to get new drawings made up.  All of this before lunch!  Amazing!

In the afternoon we worked with Tom on the next level of customisation available with the TD Tom Davies range - Couture.  With the Bespoke service we can make an adjustment of up to +/- 5mm on any measurement, with Couture we take it even further.  This opens up the possibility to complete re-design a frame for a customer.  To take the concepts of the morning's work of modifying CAD's and actually applying them for real.  By taking this next step we can be assured of an absolutely perfect fit when creating unique eyeglasses.  We take additional measurements of head dimensions and use a fitting set of frames to be sure that the nosebridge will fit perfectly.

Just as with the morning's exercise we will receive a CAD before production and have a software tool to use in office to modify the design as much as necessary while working with the design on picture.  This level of service ensures that at Ocean we are offering the very best eyewear options, bar none, so we are incredibly excited to be incorporating it into our office.

Buffalo Horn Plate

We also spent some time looking at the development of Tom's line of natural buffalo horn frames.  Buffalo horn is not a new material for eyewear, but there is definitely a growing interest in it.  Like many natural materials it is slightly unpredictable in its nature and has certain nuances or quirks which you have to respect when working with it and wearing it.

For all of these drawbacks, it is an incredible material - light, strong, comfortable and with wonderful colours.  Tom also has a wonderful take on it.  As with all his eyewear, the horn frames can be made to order, starting with the customer choosing the very two plates of horn which the frame will be cut out of - unbelievable!

It is amazing how the day passed, soon it was evening and our training day was over.  We had taken in so much information during the day and really covered so much ground, all of us were enthused with new ideas and a thoughts about how to share these with Ocean Optometry.  There's really not much more to add, the sun set, a few drinks were poured and we were reassured that by working with TD Tom Davies we were working in a relationship of mutual respect and friendship.


A few more thoughts from the day are best captured by pictures:

The finished CAD from Dr McG's design - looking forward to seeing him in this one!

The sun shining over the Hudson River

Prototypes and limited editions

The inspiring skyline

A special thanks to TD Tom Davies, Tom himself and Nathan for creating such an informative, enjoyable and fun day!