AN INVESTIGATION INTO THE AUTOMATION OF 3D MODELLED BESPOKE EYEWEAR USING INDIVIDUAL-SPECIFIC PARAMETRIC DATA AND ADDITIVE MANUFACTURING

Published Date: 01st June 2025

Publication Authors: Garrick. A

Conference Abstract: 

Introduction: Eyewear frames are mass-produced, reducing choice. There is no room or incentive to accommodate individual-specific facial features. With the new era of mass customisation provided by the advent of 3D printing, the possibility of manufacturing bespoke eyewear frames on a production line of one can become a reality. Eyewear is an essential part of life for most people, irrespective of age and social status. Its use is evident in prescription eyewear: myopic, hypermetropia, presbyopia, squints, the Leisure/fashion industry, protective wear in manufacturing, the sports sector: skiing, swimming, and for Health workers: loupes and protection. Using 3D printing will drive the development of mini-factories located close to the end user. Styles can be chosen, altered, and reproduced in less than a day. Production will be on demand, with inventory and storage being discarded. Presently, the bulk manufacturing of Eyewear is possibly harming the environment. Eyewear is mainly manufactured by centralized manufacturing systems (CMS). A few disadvantages are transportation costs, which result in CO2 emissions, and the cost of disposing of excess stock. Distributing manufacturing systems (DMS) support regional manufacturing, allow the decentralisation of production, and provide personalised products to customers in the surrounding region. The advantages are cost reduction, short delivery time, and reduced CO2 emissions. The 3D Printed eyewear with DMS will enable on-demand manufacturing whilst reducing transport and emissions. 3D printing will streamline the multiple steps and personnel involved in the manufacture of single eyewear.
Method(s): * This was an analytical, non-comparative, non-interventional, observational study. * Data collected and stored on a password-controlled personal computer * Participants sent in digital photographs taken with a measuring ruler in specific positions to enable accurate measurement reference points. * Calibrated Measurements are taken from photographs. * Eyewear frames were created using Fusion 360 (Autodesk) parametric digital workflows * Demographics: 20 participants, 80% male, All adults * The image was also rendered in CAD * Data extracted from measurements were as follows: * Interpupillary distance * Right and Left Nasopupillary distance * Ear to ear - Frontal * Forehead to ear - Straight * Forehead to ear - Slant This data was used in the parametric table, within the computer-assisted design (CAD) for sketching, and in the additive manufacturing of personalised eyewear frames tailored to individuals rather than the mass market.
Result(s): These measurements were used to create digital workflows for 3D printing personalised eyewear frames tailored to individuals rather than the mass market. There was evidence of facial asymmetry in 95% of the participants. There was a wide variation in all the measurements. Also, asymmetry in comparing the Right vs Left Nasopupillary distance (NPD) showing Nasopupillary distance was observed. Opticians usually use the Interpupillary distance (IPD) to fit prescription eyewear. This places the midpoint at the nasal bridge. IPD measurement is a significant part of eyewear prescription. It measures the distance between the left and right pupils. At the opticians, individuals with facial asymmetry will benefit from NPD instead of IPD when purchasing prescription eyewear. The use of 3D printing for the manufacturing of eyewear is not new. However, it is used in rapid prototyping and mass customisation.
Conclusion(s): This technology is a proof of concept that will enable the Rapid prototyping of eyewear frames for any industry or individual. In addition, rapid prototyping could facilitate the introduction of a clinic that makes frames for people with facial deformities, especially children with craniofacial abnormalities. The above findings show that NPD's sensitivity to identifying asymmetry will ensure that prescription eyewear is accurately fitted and reduce errors. Similarly, for facial asymmetry and, consequently, nasopupillary asymmetry (NPA), a prismatic effect in prescription eyewear can arise, as can negative effects of off-optical-axis viewing if used in prescription eyewear. 3D printing will enable the easy, quick, and cost-effective manufacture of eyewear and the customization of style and facial features. Should this technology become an actualisation, there will be no need to hold stock of eyewear frames for sustainability. This will reduce the carbon footprint associated with transporting and manufacturing eyewear.

Garrick, A. (2025). AN INVESTIGATION INTO THE AUTOMATION OF 3D MODELLED BESPOKE EYEWEAR USING INDIVIDUAL-SPECIFIC PARAMETRIC DATA AND ADDITIVE MANUFACTURING. Eye. 39, pp. 303-304. [Online]. Available at: https://dx.doi.org/10.1038/s41433-025-03831-0 [Accessed 26 February 2026].