Title: A step change in the design and manufacture of Ocular Prosthetics
Funder: Department of Health and Social Care

Abstract: Prosthetic eyes are required when eyes are surgically removed for blinding or life-threatening diseases such as eye cancer. The current process is a time-consuming artisan one, often requiring trial and error to fit the prosthesis. Over the last 12 months Ocupeye Ltd, in collaboration with Moorfields Eye Hospital and UCL Institute of Ophthalmology have designed and developed a digital end to end solution to manufacture ocular prosthetics. Our work has focused on studying the current process of the ocularist and how trial and error are used to give the best results for prosthesis movement and cosmesis. We have then examined new and existing technologies to develop a workflow to capture patient criteria, such as pattern of veins of the eye and colouration of the iris, to reduce the patient chair time from up to 2 hours on the initial consultation to under 5 minutes. This uses specialist photography with colour calibration. The anatomy of the eye socket that previously required injection of alginate (uncomfortable procedure often requiring general anaesthetic in paediatric patients) will be replaced by non-invasive optical coherence tomography scanning. Hand-made artisan manufacture of the prosthesis will be replaced with 3D printing. These methods will improve the fit of the prosthesis, leading to better prosthesis movements, reduced cost and clinic visits, and most importantly increased patient satisfaction. By using new technology colour 3D printing, manufacturing lead times will be cut from 6-10 weeks to 1 week. Our plan A" digital solution incorporates the following technologies: 3 axis 3D scanning Image capture Colour correction Image separation CAD modelling Polyjet colour 3D printing Plan &ldquo;A&rdquo; is required to develop the beta approach to a digital solution. Our long-term intention is to develop an advanced plan &ldquo;B&rdquo; digital solution, once the initial plan "A" is delivered. Deliverable Milestones Initially we will study prosthetic eye movement using digital technology to assess the mobility of the prosthesis. Next we will use the 3D printing technology to manufacture the prosthesis and compare the mobility with the analogue made prosthesis. A greater understanding of the fit and function between the ocular prosthetic and the orbital implant will allow better movements. Collaboration with the surgeon, ocularist and designer to better understand fit and function of the orbital prosthetic. An introduction of a digital workflow to the ocular prosthetic department. We will also engage further with Public Patient Involvement in the process of modernising the manufacturing process."

Lay abstract: Prosthetic eyes are required when eyes are surgically removed for blinding or life-threatening diseases such as eye cancer. The current process is a time-consuming artisan one, often requiring trial and error to fit the prosthesis. Over the last 12 months Ocupeye Ltd, in collaboration with Moorfields Eye Hospital and UCL Institute of Ophthalmology have designed and developed a digital end to end solution to manufacture ocular prosthetics. Our work has focused on studying the current process of the ocularist and how trial and error are used to give the best results for prosthesis movement and cosmesis. We have then examined new and existing technologies to develop a workflow to capture patient criteria, such as pattern of veins of the eye and colouration of the iris, to reduce the patient chair time from up to 2 hours on the initial consultation to under 5 minutes. This uses specialist photography with colour calibration. The anatomy of the eye socket that previously required injection of alginate (uncomfortable procedure often requiring general anaesthetic in paediatric patients) will be replaced by non-invasive optical coherence tomography scanning. Hand-made artisan manufacture of the prosthesis will be replaced with 3D printing. These methods will improve the fit of the prosthesis, leading to better prosthesis movements, reduced cost and clinic visits, and most importantly increased patient satisfaction. By using new technology colour 3D printing, manufacturing lead times will be cut from 6-10 weeks to 1 week. Our plan A" digital solution incorporates the following technologies: 3 axis 3D scanning Image capture Colour correction Image separation CAD modelling Polyjet colour 3D printing Plan &ldquo;A&rdquo; is required to develop the beta approach to a digital solution. Our long-term intention is to develop an advanced plan &ldquo;B&rdquo; digital solution, once the initial plan "A" is delivered. Deliverable Milestones Initially we will study prosthetic eye movement using digital technology to assess the mobility of the prosthesis. Next we will use the 3D printing technology to manufacture the prosthesis and compare the mobility with the analogue made prosthesis. A greater understanding of the fit and function between the ocular prosthetic and the orbital implant will allow better movements. Collaboration with the surgeon, ocularist and designer to better understand fit and function of the orbital prosthetic. An introduction of a digital workflow to the ocular prosthetic department. We will also engage further with Public Patient Involvement in the process of modernising the manufacturing process."

Research activity codes: 5.3 MEDICAL DEVICES
Health categories: CANCER AND NEOPLASMS;EYE