To refine the manufacture of artificial eyes through 3D technology, reducing the time and cost of producing ocular prostheses while improving patient outcomes.

Artificial eyes (also known as ocular prostheses) are hand-made through a time-consuming and labour-intensive process. Patients typically wait 4-6 weeks from their initial appointment, in which an impression is taken, to receive their prosthetic. The success of the final product, including patient comfort and realism, is highly dependent on the manual skills of the health practitioner.

The Maxillofacial Surgery Department at RBWH produces over 100 artificial eyes each year with this number expected to grow. RBWH is one of the only hospitals in Queensland to provide the service, and patients regularly fly from Cairns and other distant towns for treatment.

This is an expensive burden for patients and their families to cover the costs of one (or often more) flights, accommodation and other expenses that arise from travel. Should the prosthetic be lost or damaged, the process must be repeated, placing additional burden on the patient and health system.

Using patient-specific 3D eye models that are based on photography and 3D scanning techniques, Nicholas Puls and his investigator team have developed a prototype workflow to digitise the manufacture of artificial eyes using advanced full-colour 3D print technology in the Herston Biofabrication Institute (HBI).

In order to assess the realism of the outcomes and progress towards implementation, the primary aim of this study is to run a blinded evaluation with up to 10 patients requiring an orbital prosthetic at the RBWH (a silicone facial prosthetic which includes an artificial eye).

Patients will follow the standard-of-care pathway to have a conventional prosthetic made, alongside one containing a 3D printed eye which they will then evaluate during their final fitting process with a prosthetist.

Survey data will reveal any perceived differences or preference for 3D printed artificial eyes, while data collected during production (e.g. time to design the 3D model, time to 3D print, material consumption and cost) will highlight the feasibility of model implementation within the RBWH.

Digitising the manufacture of artificial eyes has several advantages: firstly, the 3D model can be stored as part of a patient’s digital medical records. If it is lost or damaged, this file can be re-printed and posted to the patient, whereas current hand-made eyes must begin with the patient having an appointment to attend the RBWH to repeat 4-6 week process again. Secondly, digitisation includes several opportunities to automate processes, fast-tracking design and 3D printing.

It is foreseeable that a 24-hour turnaround time could be possible for new patients travelling from afar, significantly reducing the time and cost of being fitted with a new prosthetic. However, investment in research and trials is critical to achieving this outcome.