3D Printed Lenses

Luxexcel Technology

Luxexcel is the only company in the world which can 3D print ophthalmic specialty lenses. To enable ophthalmic labs to make use of 3D printing, Luxexcel developed a turnkey 3D print solution for ophthalmic laboratories.

This in-lab technology solution will offer a revolutionary new approach to lens manufacturing and opens up new opportunities to differentiate and create unique custom ophthalmic products.

 

Ophthalmic Lenses

Traditional subtractive manufacturing has been used since the ancient Egyptians. The process used for making ophthalmic lenses has been improved significantly. The fundamental principle for manufacturing an ophthalmic lens has however remained the same.

Traditionally, a lens blank is created in a large manufacturing plant. The blank is shipped to the ophthalmic lab where it is stocked until required. When a certain lens prescription is prescribed for a patient, the appropriate blank is selected from a large inventory of blanks and the finishing process begins. Excess materials are cut away in several steps, to create the final shape and the resulting lens is polished to obtain a smooth surface. The process requires many manual handling steps and more than 10 machine processing steps.

 

Material overview

Luxexcel VisionClear: material properties

 Validation
ISO power Compliant with ISO 8980-1:2004 Focal Power.
COLTS Report available upon request
Drop ball Passed

 

Property
Refractive Index 1.53
Abbe number 45
Weight 1.15 g/cm3

 

Lens design software

With 3D printed ophthalmic lenses you will have more design freedom to create customized products for your customers. Luxexcel will provide ophthalmic labs with a custom lens design software suite called the Luxexcel VisionMaster™. With this tool, labs and eventually eye care professionals can design custom lenses for their patient.

 

F.A.Q.

How does the Luxexcel technology work?
The Luxexcel technology is an inkjet-based 3D print technology which builds lenses droplet by droplet. From a liquid material, small droplets are jetted to build the required ophthalmic lens shape. Because we let the droplets merge before they are cured, we obtain very smooth lens surfaces without any post-processes. We are able to create very accurate lenses because we use extremely small droplets, and we are able to print rapidly because we jet many droplets at the same time. To learn more about our process, please refer also to our video gallery.

What is your business model?
Luxexcel provides a full turnkey solution for ophthalmic labs, this solution is called Luxexcel VisionPlatform™. This in-lab solution includes a 3D printer, consumables, design software, print process and full service and support. We provide the full turnkey solution in order to make optimal make use of the 3D print capabilities. The lab will pay on a click fee basis and will make a volume commitment to Luxexcel. The equipment remains the property of Luxexcel.

Who will have access to this technology?
Our primary customers are ophthalmic labs. We will provide them with our enabling Luxexcel VisionPlatform™ solution consisting of hardware, consumables, software and full support. Through the labs, we will provide full customization solutions to opticians and optometrists allowing them to make full use of custom lens designs and better serve their customers.

What products can be 3D printed?
Initially, the focus will be on low volume high-value products, slab-offs, prisms, high diopters, multi-focals etc.

What ophthalmic lab can provide me with lenses?
For now, we deliver from our own facility for selected test market purposes only and make sure we stay aligned with the latest market trends. We have two printers installed in the US at IFB Solutions, Winston-Salem, NC and at Quest Vision Care Specialty Lab, Largo, FL.

I am an optician, can I get lenses?
We work through ophthalmic labs and our first machines are installed in the field. We could connect you to an accredited lab. If you would like to stay up to date please subscribe to our newsletter.

Can I get some lenses to test?
We do not sell lenses directly.  Our technology will be provided through selected ophthalmic labs. If you are an ophthalmic lab and would like to know more about our technology solution please contact us.

Do you provide prototyping for other industries like lighting and automotive?

All focus is on the ophthalmic market

Material

What materials do you use?
Luxexcel developed its own UV curable material. The material is called Luxexcel VisionClear with material properties similar to common eyewear materials.

What is the refractive index of the material?
Our material has a refractive index of 1.53

What is the Abbe value of your material?
Our material has an Abbe value of 45

What is the weight of your material?
Our material has a weight of 1,15g/cm3

Are 3D printed lenses at ISO/ ANSI level?
We comply with ISO 8980-1:2004 Focal Power tested by Colts Laboratories. You can review the report here. We take into account ANSI standard.

Do 3D printed lenses pass the FDA drop ball test?
Yes, our lenses do comply with the FDA drop ball test, including both the big and small ball.

What are the operating temperatures?
Between -20° C and + 50° C ( -0.4° F / + 140° F).

What are the values for transparency?
Transparency: 99.4% (per mm)
Haze: 0.1%

Coating & Edging

Coating compatibility
Luxexcel lenses are compatible with various coatings typically used in the ophthalmic industry. Through partner companies we are compatible with:

  • Hard coats/Anti-scratch coatings
  • Blue light / UV filter
  • Anti-reflective coating
  • Tinting
  • Mirrors

We are currently developing:

  • Polarization
  • Photochromic

Can your lenses be edged?
Our process is compatible with both stone-based and tool-based edging processes.

Lens Design

Do you have lens design software?
To make use of the benefits of 3D printing Luxexcel has developed a lens design suite called  Luxexcel VisionMaster™ which allows ophthalmic labs to create their lens designs. The software is developed to design lenses which are difficult to manufacture and is ideal for designing specialty lenses.

 
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