University of Waterloo researchers have developed a digital manufacturing platform combining new silicone materials with 3D printing technology that can produce patient-specific contact lenses in as little as 20 minutes, potentially allowing specialized lenses to be designed, manufactured, and dispensed during a single optometrist visit.
Most contact lenses are manufactured in a limited range of sizes and shapes rather than custom-made for individual eyes, and patients with irregularly shaped corneas who require rigid lenses often need several appointments over weeks or months before receiving a proper fit. The Waterloo platform combines custom lens design software with a newly developed hydrophilic silicone material engineered specifically for 3D printing, since conventional silicone is generally incompatible with additive manufacturing. The software designs a lens with an inner surface matching the patient’s cornea and an outer surface providing vision correction, while a separate ultra-thin, non-contact coating process addresses stair-step imperfections that can form on 3D-printed curved surfaces, smoothing the lens without altering its customized shape.
Laboratory testing has confirmed the lenses are biocompatible, and the team is preparing for in vivo studies. Researchers have filed a provisional patent for the hydrophilic silicone material and are preparing a full patent application, and are working with the Centre for Vision and Eye Research, a joint research institute of the University of Waterloo and Hong Kong Polytechnic University, to advance the technology toward commercialization. The project received a Gold Medal at the Shanghai International Exhibition of Inventions in June 2026. The study, “Patient-specific hard contact lenses fabricated by vat photopolymerization printing and non-contact fluidization coating,” was published in Materials & Design.
KEY QUOTES:
“We are very excited about this work because it brings us closer to contact lenses that are truly personalized. 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.”
Dr. Shirley Tang, Professor, University of Waterloo Department of Chemistry
“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. The novel hydrophilic silicone material we created, combined with our manufacturing process, produces smooth, transparent lenses that are comfortable to wear.”
Dr. Sayan Ganguly, Research Associate, University of Waterloo Department of Chemistry
