Challenge
To create a bespoke eye cover for a patient with a large tumour behind the left eye.
Design Approach
Using non-contact 3D scanning to create a model of the patient’s face that was then used to create a bespoke eye cover suitable for 3D printing.
Delivery
The completed device was accepted by the patient and the clinical team, three days after the initial scan was taken.
Background
The patient has a diagnosis of left maxillary alveolar rhabdomyosarcoma. Clinically, his eye was protruded. Initially, this was covered with a non-woven swab, adhered with tape. There was also a trial of a commercially available plastic eye covering, however this was insufficiently concave to accommodate the concern and was not satisfactory to the patient.
Objectives
After discussing with the RIU team, the key objectives were to create a bespoke eye covering that was; plain black, discrete, light occluding, easily applied and removed, accommodate further potential for progression of the disease, retain moisture to reduce further drying out of the corneal surface and be comfortable, thus facilitating minimal handling by the patient, his family, and staff to reduce infection risk (particularly COVID-19).
Results
Using a non-contact 3D scanner, a digital model of the patient’s face was created in a single 5-minute visit. On outline was created that extended beyond the borders of any oedema associated with the rhabdomyosarcoma. Using computer aided design (CAD) software, a structure was designed with a 5mm clearance between the highest point of the pupil and the inside of the cover. Two attachment loops were added to the model for use with an adjustable elasticated headband. The eye cover was exported for printing on the Figure 4 3D Printer in the Pro-Black 10 biocompatible material. The 3D scan was performed on a Wednesday morning, with the finished cover assessed and accepted by the patient and clinical team on the Friday afternoon.
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- School of Architecture and Product Design UL
