•Precision plastic biaspheric lens having high and uneven thickness was developed using injection molding process.•A hybrid ANN and PSO technique was employed to predict the optimal process parameters.•Mould with aspheric profiles was prepared using single point diamond turning machine.•Surface characterisation like form, waveiness and surface roughness of mould and moulded bi-aspheric lens are measured.•Aberrations in the injection molded lens were studied using Shack-Hartmann Wavefront Sensor. Injection molding of bi-aspheric lens using polycarbonate material with minimum variation in volumetric shrinkage is crucial for optical quality and is more challenging task among the researchers. In this paper, a hybrid artificial neural networks (ANN) and particle swarm optimization (PSO) technique is used to predict the optimal process parameters of injection molding process of the bi-aspheric lens. The developed ANN network (7-13-6) was trained as well as tested with experimental data sampled from statistical methods. The well trained and tested ANN network was coupled with improved PSO algorithm as a hybrid ANN-PSO to optimize the injection molding process parameters. The optimized injection molding process parameters obtained from hybrid ANN-PSO algorithm are validated with experiments using J. S. W injection molding machine. It is observed from the lens quality parameters that the proposed hybrid ANN-PSO method optimized the injection molding process of the bi-aspheric lens with an optical power of 27.73 Diopter and the lens posses seventh order spherical aberrations.