Compared to traditional biological lenses that are used to correct optical systems, such as contact lenses, vision correction surgery, and corneal and lens replacement, 3D printed biological lenses offer a customizable solutions. However, the layer-by-layer principle of 3D printing leads to a staircase effect, which cannot meet the critical requirements of surface quality during the manufacturing process of biological lens, particularly with soft materials. Here, a liquid-phase printing strategy and a surface tension-dependent (STD) post-processing method are proposed that use the surface tension of the liquid to reconstruct the air-liquid interface. This eliminates the staircase effect caused by the stacking of units during 3D printing. The coordinates of integrated printing enable high-accuracy shape control of soft materials. Using a typical biological lens as an example, this method improves the surface quality of printed lamellar corneal substitutes (LCS) from ±20.0 to ±0.2 µm and reduces thickness feature size from ±500 to ±150 µm. This approach can match human cornea curvature and thickness, achieving ≈85% visible light transmittance and biocompatibility. Liquid-phase 3D printed biological lenses outperform molded ones in animal experiments. This method can advance artificial biological lens printing research and holds promise for future clinical applications.
Keywords: 3D printing; corneal substitutes.
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