University of Waterloo team 3D-prints custom contact lenses in about 20 minutes

Researchers from the Department of Chemistry at Canada's University of Waterloo have developed a 3D printing approach intended to produce personalized contact lenses in about 20 minutes in a single appointment, New Atlas reported, citing the university. The process uses specialized software to create a digital model of the lens. The inner surface is designed to match the unique shape of the patient's cornea, while the outer surface provides the required vision correction. The work targets people with irregularly shaped corneas who often face high costs and multiple fitting appointments for custom lenses. Because standard silicone is poorly compatible with 3D printing, the researchers developed a new hydrophilic silicone formula that can be built layer by layer. Layered printing can leave stair-step surface imperfections that affect comfort and optical clarity, so the team applied an ultra-thin coating that smooths the surface without changing the customized shape. Laboratory testing showed the lenses are biocompatible, and the researchers said the 3D-printed lenses deliver optical clarity and mechanical performance comparable to commercial contact lenses. Chemistry research associate Dr. Sayan Ganguly said the novel hydrophilic silicone material combined with the manufacturing process produces smooth, transparent lenses that are comfortable to wear. Next steps include preparing for real-world testing and completing the patent process.