3D Printing Smart Eyeglass Frames: A Review

Eyeglasses are typical correctors for refractive error eye disorders. They are commonly placed on frames expected to be stylish and durable. Currently, the consumer demand for sustainable and eco-friendly frames is gaining interest, especially since conventional frame manufacturing methods follow a subtraction of large blocks of wasted scrap material. Additive manufacturing (AM) promises better economic feasibility due to reduced tooling, storage, and material costs, as well as enhanced mechanical properties, by inducing nanomaterials and composites. Moreover, synergism between AM and digital design has led to a rising interest in smart or electronic eyeglass frames. This systematic review assesses commercial eyeglass frames that use standard materials with long-lasting resistance, durability, comfort, and versatility with various materials such as metals and polymers. It also explores the design aspects of these eyeglasses and their correlation with the utilization of artificial intelligence trained computer-aided design software. Beyond the appealing eyeglass frame technology, a review of smart frame design, in which electronic sensors and chips are embedded, is also included. Furthermore, this review comprises various applications for 3D printing of frames including commercial and biomedical applications. Other reviewed topics include the side effects, health risks, shortcomings of AM techniques and materials, and void formation inside the matrix that propagates fatigue and shrinkage or density change during solidification.