A novel, efficient 3D-printing based manufacturing process for custom ocular prostheses

Ocular prostheses are part of a substantial global market for ocular implants. However, demand for custom ocular prostheses (COPs) can outpace supply at clinics due to the slow pace of prosthesis manufacturing and limited supply of ocularists, particularly in emerging markets such as India. Existing manufacturing methods for COPs involve multiple stages of casting and molds with limited quality control, resulting in time-intensive trial and error with patients to achieve a comfortable fit. Through collaboration with the LV Prasad Eye Institute (LVPEI) in India, the authors improved manufacturing process efficiency for COPs and without significantly increasing cost or decreasing customizability. A time study of the current process showed that no single step was a dominant contributor to process time, necessitating a holistic change to the manufacturing process. The modified process uses dip coating of a 3D printed internal body made from a scanned impression. Based on a timed experimental trial, the modified process has a projected daily COP production rate increase of 100% compared to the existing process. A study of produced COP quality showed accumulated error of critical dimensions within reasonable limits, with the greatest error being less than 65% of maximum acceptable error.