A new digital manufacturing platform developed by researchers at the University of Waterloo could change how contact lenses are manufactured, with the potential to produce patient-specific lenses in as little as 20 minutes during a single visit to the optometrist.
In a news release, the university said the platform combines custom lens design software, a newly developed silicone material and advanced 3D-printing techniques to manufacture rigid contact lenses tailored to an individual’s eye.
The researchers said the approach could reduce the need for multiple fitting appointments, particularly for patients with irregularly shaped corneas who often require specialized lenses.
“We are very excited about this work because it brings us closer to contact lenses that are truly personalized,” said Dr Shirley Tang, professor in Waterloo’s Department of Chemistry.
“Our technology produces lenses with patient-specific surfaces for a precise fit while delivering the optical clarity and mechanical performance expected of commercial contact lenses.”
According to the University of Waterloo, most contact lenses are produced in a limited range of sizes and shapes rather than being custom-made. While conventional soft lenses suit many users, patients with irregular corneas often need rigid lenses, with the fitting process sometimes taking weeks or months.
The research team developed the manufacturing platform to address these challenges by enabling customized lens production through additive manufacturing.
Silicone is widely used in contact lenses because of its biocompatibility and oxygen permeability, but conventional silicone materials are generally unsuitable for 3D printing. To overcome this limitation, the researchers developed a new hydrophilic silicone formulation designed specifically for additive manufacturing while retaining the properties required for contact lens use.
“Our software designs a lens with an inner surface that precisely matches the patient’s cornea and an outer surface that provides the required vision correction,” said Dr. Sayan Ganguly, chemistry research associate at the University of Waterloo.
“The novel hydrophilic silicone material we created, combined with our manufacturing process, produces smooth, transparent lenses that are comfortable to wear.”
To improve optical clarity and wearer comfort, the team also developed an ultra-thin, non-contact coating process that smooths the layer-by-layer surface of the printed lenses without changing their customized shape or affecting optical performance.
The university said laboratory testing confirmed the lenses are biocompatible, and the researchers are preparing for in vivo studies. A provisional patent has been filed for the hydrophilic silicone material, with a full patent application in preparation.
Working with the Centre for Vision and Eye Research, a joint research institute of the University of Waterloo and the Hong Kong Polytechnic University, the researchers are advancing the technology toward commercialisation.
The project received a Gold Medal at the Shanghai International Exhibition of Inventions in June 2026. The findings were published in the journal Materials & Design in the study, Patient-specific hard contact lenses fabricated by vat photopolymerization printing and non-contact fluidization coating.
