Today’s 3D printers can make everything from parts to fix annoying chains on ceiling fans to wheelchairs that can help turtles walk. Advanced 3D printing technology is now being used to manufacture contact lenses. The breakthrough could help patients with irregularly shaped corneas get custom lenses more quickly and affordably.

Seeking a better patient experience

Most people who wear contact lenses have soft lenses fitted by an optometrist, who compares their eye measurements to a selection of standardized sizes and shapes. But patients with irregularly shaped corneas often require custom hard lenses. These lenses provide better vision correction and support corneal health, but they can be expensive and time-consuming to manufacture. To solve this, a study recently published in the journal Materials and design describes a digital manufacturing platform that promises to expand the design possibilities of patient-specific lenses.

“We are very excited about this work because it brings us closer to contact lenses that are truly personalized,” Shirley Tang, a co-author of the study and a materials chemist at the University of Waterloo in Canada, said in a statement. “Our technology produces lenses with patient-specific surfaces for a precise fit while delivering the optical clarity and mechanical performance expected from commercial contact lenses.”

a perfect combination

The platform combines custom design software, a novel silicone material and advanced 3D printing technology to produce contact lenses in about 20 minutes. With this speed, lenses could be prescribed and manufactured during a single visit to the ophthalmologist.

Since conventional silicone is not compatible with 3D printing, the researchers developed a custom hydrophilic silicone formulation. The material can be printed layer by layer, while retaining the properties necessary for contact lens applications.

“Our software designs a lens with an inner surface that exactly matches the patient’s cornea and an outer surface that provides the necessary vision correction,” added study co-author Sayan Ganguly, a research chemist at the University of Waterloo. “The novel hydrophilic silicone material we created, combined with our manufacturing process, produces soft, clear lenses that are comfortable to wear.”

One layer at a time

Since this custom lens is built layer by layer, the team also developed an ultra-thin non-contact coating. The coating smoothes out small surface ridges that can form during the printing process. According to the team, the coating improves clarity and comfort without compromising the custom lens shape or optical performance.

Laboratory tests also showed that the lenses are biocompatible, meaning they are safe for use with living tissue. The team is also preparing its lenses for studies involving living organisms. They are also working on a full patent application for the hydrophilic silicone material.

Tang said CBC News that one of the objectives of the work is to greatly reduce the cost of hard lenses, which can range between $500 and $1,500. He said current costs typically come from manufacturing, multiple visits to the optometrist and lens fitting.

If the technology eventually comes to the clinic, getting custom contact lenses could be as simple as scanning your eyes, waiting a few minutes for the 3D printer to work its magic, and walking away with lenses made especially for you.

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