Across all industries, 3D printing has come to the forefront as a disruptor in developing completely new products and more efficient manufacturing processes. It is now offering a solution for custom prescription lenses. 3D printing has the most impact where there is a need for volume, and individual customization, which is exactly what prescription lenses are all about.
3D printed lenses do not require huge inventories, a complex supply chain or have a limited product design. 3D printing offers ophthalmic labs and eyewear companies an opportunity to maximize the industry’s potential. A key element is the customization of the lenses to tailor the needs of the patient. Optimizing the lens design for 3D printing results in a good looking lens that satisfies the patient.
Showcase unique 3D printed lenses: custom high power prism reader lens
A US-based lab had a client who wanted to sell an upgraded low-vision aide. The product they would like to provide was a line of reading glasses with high plus base powers, each combined with prism. With legacy lens technology, the lenses were thick and cosmetically unappealing, created excessive glare, and were heavy and uncomfortable to wear.
Traditional technology vs. 3D printing of lenses
The available technology to make a better product using traditional lens manufacturing was not good enough. Attempts slowed down the production flow in the lab, and the yield was low. There was much room for improvement for the lab, customer, practitioner and patient, but no known path to achieve it.
Luxexcel created optimized 3D printed lens designs for each of the desired SKUs using a combination of our proprietary 3D printers, print material and printer software. The result is a significant reduction in lens thickness, curvature and weight, resulting in a cosmetically appealing product that will deliver better vision for the patient. The lab was able to demonstrate commitment to excellence in customer service by delivering what their client needed. The client has a new line to sell to their eye care practitioner customers, delivering a vast improvement over legacy product. Through our partnership and the power of Luxexcel’s patented technology, we solved an existing problem together and created a completely new product: the world’s first 3D printed prism reading glasses.