Design, Production and Study of Flexible Acrylic Keratoprosthesis.

Purpose: To design, produce and implant one-piece flexible acrylic keratoprostheses for the treatment of corneal blindness.

Methods: A protocol was developed to produce flexible acrylic sheets of differing properties, and their mechanical characteristics were evaluated. To assess in vitro toxicity, an MTT assay was performed. 3D-printed injection molding technique of this material was designed to fabricate flexible keratoprostheses with complex shapes. A pilot study involving a 3-month implantation in a rabbit was conducted, including histological analysis.

Results: Flexible acrylic copolymer sheets of high clarity were produced by free radical polymerization. Their mechanical properties and refractive indices could be altered with different material formulations. They demonstrated no in vitro toxicity in human corneal cells via MTT assay. 3D printed silver molds allowed for the production of keratoprostheses of complex shapes made from these materials. Surgical implantation resulted in clear implant at 3 months.

Conclusions: Molding of flexible acrylic allows for production of one-piece keratoprostheses of a complex shape and opens new possibilities for the treatment of corneal blindness.