Researchers are using 3D printing for the production of eye implants

Researchers at the University of East Anglia have advanced eye device technology with the introduction of a new resin for 3D printing intraocular eye devices. This innovation has the potential to improve the production of ocular implants used universally in cataract and refractive surgery. The article, titled “Stereolithographic Rapid Prototyping of Clear, Foldable, Non-refractive Intraocular Lens Designs: A Proof-of-Concept Study,” was published in the journal Current Eye Research.

An artificial intraocular lens (IOL) is primarily needed for people with cataracts, a condition in which the eye’s natural lens becomes cloudy, obscuring vision. They can also be used to correct refractive errors such as nearsightedness (myopia), farsightedness (farsightedness), and presbyopia (when the eyes gradually lose the ability to see things clearly up close, as a normal part of aging).

“For the first time, we have developed a resin that can be used to print ocular devices directly,” said Dr. Aram Saeed, Associate Professor of Healthcare Technologies at UEA’s School of Pharmacy and lead author of the study. “Although still in the early stages, the ability to 3D print these lenses could significantly improve eye care for patients, providing unprecedented levels of customization and design precision that can lead to better clinical outcomes.”

Historically, IOLs have been made from a variety of materials, including glass and silicone, although more recently the industry has evolved significantly to predominantly use acrylic materials. Currently, hydrophilic and hydrophobic acrylic are the most commonly used materials due to their excellent optical clarity, flexibility, biocompatibility with the body, and for their stability and safety inside the eye.

Current IOL manufacturing methods use turning and casting techniques. While these methods offer the production of well-designed and high-optical quality devices, they also come with inherent limitations, particularly in terms of design complexity and customization.

“3D printing could significantly improve the production of ocular devices, not only improving speed and precision in production, but also enabling greater complexity and customization in design. Our proof-of-concept work is the first in a series that will detail our developments in this area and set the stage for transforming eye care practices globally,” said Dr. Aram Saeed. “Our work combines materials science with health care technology and requires extensive know-how in the development of these types of eye devices. As we continue to publish our discoveries and share our progress, we aim to be at the forefront of the industry, collaborating with industrial partners and researchers around the world to refine and improve the technology.”

Although still in the early stages of development, the innovation could have several advantages:

• Custom lenses: 3D printing could create custom lenses for each patient’s eye shape and visual needs, potentially improving vision correction and comfort.
• Faster production: Compared to traditional methods, 3D printing has the potential to enable faster design, testing and manufacturing of lenses. This speed could reduce the time between diagnosis and surgery, providing faster care for patients.
• Complex designs: 3D printing makes it possible to create complicated lens shapes that were previously difficult to manufacture. These models could better address a wider range of vision problems.
• Cost reduction: By using 3D printing, the production cost of custom or high-quality lenses can decrease, making them more affordable for more patients, especially in economically disadvantaged regions. This could lead to better overall public health outcomes.
• Imaging compatibility: Researchers hope that in the future, combining 3D printing with advanced imaging technologies could help produce lenses that optimally fit patients’ eyes, reducing the need for adjustments or complications after surgery.
• Material innovation: 3D printing enables the development of new materials with improved optical performance. This could lead to lenses that not only correct vision, but also improve it.

The study found that the 3D printed lenses have good optical clarity and can be folded and implanted in a human capsular bag.

“If successful in further development, this new technology could transform the industry, enabling portable manufacturing solutions, particularly beneficial in remote and economically disadvantaged areas,” said Michael Wormstone, Emeritus Professor at UEA’s School of Biological Sciences and co-author of the study. . “It also has the potential to support the production of premium custom lenses that could improve surgical outcomes in more advanced healthcare settings.”

The team’s efforts have been recognized by the award of a United States patent awarded to UEA Enterprise Limited, a business entity of the university focused on driving innovation and commercializing research.

Researchers at the University of East Anglia continue to work closely with industry partners to refine the technology. For example, additional work has been carried out to ensure that the process works accurately on a larger scale and to increase the print resolution to improve dimensional accuracy. It is hoped that clinical trials could begin in the next few years.

Dr Saeed and Prof Wormstone have a strong partnership with the department of ophthalmology at Norwich and Norfolk University Hospital (NNUH), which brings valuable clinical insights and visionary approaches to their work with both the University of East Anglia and the hospital’s members pioneering. Norwich Research Park.

“This innovation has the potential to enable the production of lenses that match the patient’s specifications in terms of design and optical performance,” said Mr Anas Injarie, a leading consultant ophthalmologist at NNUH with over 20 years’ experience. “For premium markets, it represents an exciting opportunity to provide personalized treatments that could enhance patient satisfaction and surgical success.”