3D-Printed, Custom Contact Lenses Are Possible, and Can Be Made in 20 Minutes

If you have abnormally shaped corneas or a demanding vision condition contact lenses — such as nearsightedness, farsightedness or astigmatism — you know that finding the right fit can take weeks of trial and error. That could all change with 3D printed contact lenses that take less than 20 minutes to produce.

A press release published on Tuesday reports that researchers at the Department of Chemistry at the University of Waterloo in Ontario, Canada, have developed a contact lens system that uses custom software to digitally map each patient’s cornea, that is, the clear, dome-shaped outer layer that covers the front of the eye.

Instead of relying on pre-made lenses in fixed sizes, the platform will create custom-made lenses that adapt to your cornea’s shape and size in rapid manufacturing time — allowing clinics to design, print and dispense custom lenses in a single visit. The team also invented and provisionally patented a 3D printed silicone designed for patient safety.

“Our goal is for printed lenses to perform equally well with existing contact lenses in terms of surface properties, including smoothness to prevent abrasion, stability under normal cleaning conditions and oxygen retention,” Shirley Tang, one of the researchers who conducted the study, told CNET via email.

How a 3D printed contact lens system works

Contact lenses are usually made of silicone, but that material will not work with 3D printer. Waterloo researchers have created a hydrophilic (aka water-loving) silicone formulation that works with a DLP (digital light processing) 3D printer and does not compromise safety or oxygen flow.

According to a research paper published by the Waterloo team in June, corneal lens geometry is generated using algorithms that then generate thickness maps for 3D printing.

“Our software designs a lens with an inner surface that precisely matches the patient’s cornea and an outer surface that provides the necessary vision correction,” said Sayan Ganguly, a chemistry research associate at the University of Waterloo, in a press release.

What prescription, contact lens results are right for you.

Since 3D printing builds materials layer by layer, this can cause imperfections in the curved surface, such as contact lenses, leading to discomfort and reduced clarity. The researchers overcame this obstacle by designing a thin layer that was smooth without defects while maintaining both structure and clarity.

Ideal patients for these 3D printed lenses

This 3D printing technology only produces hard contact lenses, which Tang said are generally good for people whose vision can’t be adequately corrected with soft lenses. This can include those with abnormal corneas (such as keratoconus), high or abnormal astigmatism, corneal scarring or complications following eye surgery.

“Because these conditions vary greatly from person to person, hard/hard contact lenses must be fitted by a qualified optometrist to ensure optimal vision, comfort and eye health,” says Tang.

An eye doctor can determine if you need hard contact lenses instead of soft contact lenses.

Future testing and sales

During lab tests with human corneal epithelial cells, the team confirmed that the 3D printed contact lenses are safe to use without harm, but they are preparing to conduct further studies and later market the product.

According to Tang, the Waterloo team believes their technology will make custom rigid contact lenses more affordable. Today, these commercial lenses cost anywhere from $500 to $1,500, including professional fitting, follow-up appointments and the lenses themselves.

“We think our technology can help democratize access to strong contact lenses by reducing their cost and simplifying the fitting process,” Tang said.