2.1. Main Materials used in contact lenses fabrication
Current ocular treatments are outperformed by contemporary contact lenses materials in terms of drug delivery. It is necessary to further modify the base polymer structure of these devices in order to support and enhance the therapeutic outcome [
17]. The most prevalent alteration techniques are molecular grafts, particle encapsulation, and soaking [
18]. Despite proof of the improved performance of these materials, additional work is required to bring them to the stage of commercialization. The greatest market hurdle is the cost of clinical trials and the manufacturing needs.
However, the functionalities of a material used for contact lenses fabrication can be employed as multifunctional drug-binding mechanisms. For instance, the insertion of ionic monomers can generate binding sites for a polar medication, allowing the lens to hold the drug until it is administered to the eye [
2].
Double-network/interpenetrating hydrogels and pH-responsive polymers are two classes of materials that have experienced rapid growth. Although there has been considerable interest in areas such as liquid crystal contact lenses [
19,
20,
21], the number of research articles in these areas remains relatively low in comparison to other technologies.
Double-network/interpenetrating hydrogels create a new composite gel by linking the gel networks of two gels [
22]. Instead of a typical copolymer gel, the network of one gel is interlaced with the network of the other gel. This is a small but essential distinction; for instance, two polymers having different functional groups, meaning they cannot be copolymerized, could create a double network gel whose density could be tweaked in order to support optimal ophthalmic bioactive molecules [
23].
Figure 1A exhibits a schematic representation of different hydrogels structure, demonstrating the main structure difference between traditional single polymer networks, double-network and cross-linked double network. Temperature- and pH-responsive hydrogels are based one macromolecules whose conformational shape change when exposed to a certain temperature or acidic/basic conditions. pH variations in the body (e.g. caused by inflammation [
24]) induces protonation, and therefore conformational changes in the polymer, enabling the release of the drug. As such, their potential as drug-delivery mechanisms for biomedical devices growing [
24,
25,
26].
Figure 1B, C exhibits a schematic representation pH-responsive hydrogels in both acidic and basic medium.
The terms “hard” and “soft” are frequently employed as broad labels for contact lenses. Hard contact lenses are gas-permeable durable devices, whereas soft contact lenses are constructed of a flexible, high-water-content network which facilitates gas permeability dependent on the water ratio content. Although hard lenses are often referred to as rigid gas-permeable lenses (RGPs), this is not strictly correct since numerous counterexamples could be brought forward [
29,
30,
31]. A soft contact lens (SCL), on the other hand, is a very flexible, oxygen-permeable polymer with higher water content. Because of their flexibility, SCLs adapt to the shape of a user’s eye significantly faster than stiff lenses. SCLs can be disposed of on a daily, weekly, or monthly basis [
32,
33]. These broad definitions of contact lenses can provide some insight into their material qualities, but not always. Materials used in hard and soft lenses, frequently overlap. Although they both use silicone materials, there are differences in the chemical composition, structuration, gel network, water content, etc. Derivatives can help to broaden the spectrum of feasible contact lenses and their attributes. Contact lenses features are fairly extensive, and there is a plethora of existing devices on the market to reflect this [
18].
Table 1 summarizes the main polymer materials used for the fabrication and the CLs features derived from used material.
In terms of drug accommodation, silicone hydrogels and other hydrogels are believed to be the optimal materials for the fabrication of contact lenses [
34]. Early hydrogel contact lenses made by polymerizing 2-hydroxyethyl methacrylate (HEMA) didn’t let enough oxygen into the eye. The addition of different hydrophilic monomers to HEMA polymer formulations increased the water content and made it easier for oxygen to pass through. However, HEMA-based hydrogels cannot be worn for more than 6-7 days [
34]. Silicone hydrogel lenses, on the other hand, allow an important amount of oxygen to pass through and can be worn for 29 days [
35].
Contact lenses facilitate drug flow to the eye surface for more than 30 minutes, which, compared to the eye drop delivery of roughly two minutes is highly advantageously. This means that the bioavailability of drug on the cornea is superior because contact lenses deliverthe loaded bioactive drugs for longer extentthan conventional eye drops devices. As a result, the amount of the drug in the body’s bloodstream is cut down, and so are the possible side effects. Drug-filled contact lenses can be worn by patients for a longer time, which reduces the number of times they need to be administered medication [
36].
At first, there were no investigations on medication release from contact lenses. The first drug-infused hydrogel contact lens was created in 1965. The lenses were immersed in an aqueous solution containing 1 percent homatropine, which elicited full pupil dilatation in patients for longer than eye drops alone. Following this, there was interest in the delivery of pilocarpine using contact lenses for the treatment of glaucoma and an increasing number of studies began examining contact lens efficacy
via in vitro and
in vivo experiments addressing various ophthalmic conditions [
16].
Under optimal conditions, there is at least a 50% corneal bioavailability for the drug supplied by contact lenses. In attempt to more correctly predict the corneal bioavailability, a mathematical model for drug transport from contact lenses has been devised; however it neglects some contact lens issues, such as swelling and the interaction with the lodging network [
37]. It has been proven that the rate of radial diffusion, the rate of drug equilibrium between the contact lens and the tear film, and the ratio of drug uptake by the cornea are the three most influential parameters on corneal bioavailability. Predictions place corneal bioavailability between 50 and 70 percent [
34].
Poly methyl methacrylate (PMMA), cellulose acetate butyrate (CAB), siloxy methacrylate (SMA), and fluoro-siloxymethacrylates (FSA) are some of the polymers that can be utilized to make stiff contact lenses. Mulle and Ohring were the first to develop rigid PMMA contact lenses in 1936. CAB was approved by the FDA in 1978 as an alternative for PMMA due to its superior gas permeability. SMA sparked the development of a new generation of contact lenses with exceptional stiffness and gas permeability by combining a methacrylate backbone with siloxane groups. Surface wetness was a prevalent concern due to SMA’s high lipophilicity, which resulted in surface scratches and a build-up of lipid surface deposits [
34].
Soft contact lenses have the advantages of comfort and biological tissue compatibility over earlier hard contact lenses. Because oxygen dissolved in water can be provided to the cornea, the oxygen permeability of a hydrogel contact lens is primarily determined by its water content. N-vinyl pyrrolidone (NVP) is a typical hydrophilic monomer that is widely used to raise the water content of soft contact lenses [
39]. However, NVP can also increase the relative evaporation rate of water, resulting in a rough surface on the lens. This phenomenon is not suitable for soft contact lens wearers, but it can help with drug loading and release in lenses with drugs [
18]. Pores were generated within the hydrogels during polymerization by adding NVP and 20 percent to 40% V/V water to the HEMA contact lens in one study. Hydrogels with microstructural changes had more water content, which improved drug loading and resulted in a more optimal release profile [
30]. Furthermore, when poly(vinyl pyrrolidone) is copolymerized with HEMA, it was found an increasing surface hydrophilicity and reduce surface friction. Conversely, ion ligand copolymerization of the highly negatively charged anionic methacrylic acid (MAA) monomer with 3-Methacryloxypropyltris(trimethylsiloxy)silane (MPTS) and HEMA can improve cationic drug loading
i.e. Gatifloxacin (GFLX) and Moxifloxacin (MFLX) antibiotics [
40]. The released antibiotics volume of the new MAA-MPTS-HEMA lenses was found to be considerably higher throughout 72 hours than that of the commercial, etafilcon A and polymacon (P < 0.01) lenses. Furthermore, the concentration found in the cornea and aqueous humor was higher than those for the eye drop groups.The carboxyl groups of MAA, on the other hand, attract positively charged proteins like lysozyme, resulting in a large accumulation of protein on both surfaces of the lens.
The corneal edema caused by overnight lens usage, which promotes excessive water build-up (favoring bacterial growth), was addressed by adding silicone to the hydrogel which increase oxygen permeability and decreased the equilibrium water content. Silicone hydrogel contact lenses are often made out of i) silicone-based polymers such as poly-dimethylsiloxane (PDMS), tris-trimethylsiloxysilyl (TPVC), tris(trimethylsiloxy)- methacryloxy-propylsilane (TRIS), or other siloxane macromers and ii) as well as hydrophilic monomers like HEMA, N, N-dimethylacrylamide (DMA), or NVP. TRIS-DMA-NVP-HEMA contact lenses overcome the most limitations related to the aforementioned compositions by presenting the best balance between oxygen permeability, equilibrium water content, hydrophilicity and reduced protein film formation [
32]. Consequently, soft contact lenses with tailored features could be achieved according to specific requirements by combining the materials with required properties and the appropriate fabrication method. Another study investigated a complex composition based on TRIS-NVP-MAA-poly(ethylene glycol) methacrylate (PEGMA). The hydrogel presents a nice balance between oxygen permeability, water absorption capacity, contact angle, modulus and protein adsorption when compared to some commercial contact lenses (e.g. Acuvue Advances or Cooper vision). The contact angles of the TRIS-NVP-MAA-PEGMA based CLS were lower than that of Pure Vision and similar to that of Acuvue Oasys and Acuvue Advance. The modulus ranged from 1.42 MPa to 0.69 MPa depending on the PGEMA content while the moduli of commercial CLs range from 0.3 to 1.52 MPa e.g. CIBA Vision moduli are higher (1.0–1.52 MPa) On the other hand the friction coefficient varied between 0.288 to 0.075 as the PEGMA content increased while that of Clariti 1 day, (CooperVision) is 0.069. Another design parameter is oxygen permeability, which range between 73.0 barrers to 45.3 barrers and place TRIS-NVP-MAA-PEGMA contact lenses comparable or superior to 1-Day Acuvue (21.4 barrers), Biomedics XC (44 barrers), and Biomedics 38 (8.4 barrers) commercial contact lenses [
41].
2.2. Manufacturing methods
Manufacturers have created a number of ways for producing contact lenses that contain and release active ingredients. Lathe-cutting, spin-casting, and cast-moulding are now the most extensively utilized contact lens manufacturing procedures. Diverse manufacturing procedures will have to comply with significantly different techniques adapted with respect to material specificities. The characteristics of the final lens may be affected by these various material manufacturing stages. Solid buttons of dehydrated material are used to make lathed lenses. The buttons are typically bulk polymerized over a long period of time [
42]. Spin-casting is the process of injecting a mixture of monomers into a mold that is spun at a computer-controlled speed. The form of the lens front surface is determined by the shape of the mold. The centrifugal force created by the mold’s spin speed, the surface tension and friction forces between the mold and the polymer, and the influences of gravity all influence the form of the lens’ back surface [
42]. Spin-casting is much faster than button manufacturing in the lathing process, generally requiring less than an hour to polymerise the finished lens. In the cast-moulding process a small amount of monomer is placed between two casts to directly form the lens. The polymerisation process is very fast which is one of the reasons why this is the method of choice for bulk (disposable) lens manufacture [
42].
In terms of necessary materials, design flexibility, and complicated geometries, all of these techniques are limited to some level. Additive manufacturing (AM) methods may be preferable for producing personalized, multi-functional and smart contact lenses [
43].The additive manufacturing, also known as 3D printing technique, is the most emerging technology in the manufacturing field, especially because of its control over dimensions with the help of a computer aided design (CAD) model of the object piled up into a 3D architecture with high accuracy. The technology is appealing since it saves time and money while also requiring little post-processing of printed goods. Compared to other traditional manufacturing technologies, AM allows for precise item replication and the production of multiple products at the same time [
44,
45]. Selective laser sintering (SLS), fused deposition modeling (FDM), photocuring stereoscopic printing, stereolithography apparatus (SLA), and digital light printing (DLP)are some of the 3D printing processes used to manufacture contact lenses [
46]. Because of the excellent resolution of the printing and the small thickness of the printable layers, light-curing-based 3D printing methods (such as SLA and DLP) are frequently used in the fabrication of such optical devices [
47,
48].