Polymeric Materials for Ophthalmic Lenses: A Systematic Review on Structure, Properties, Manufacturing and Sustainability

Abstract

Polymeric materials have largely replaced mineral glass in ophthalmic lenses owing to their low density, impact resistance, optical performance, and manufacturing versatility. Despite their widespread use, the available literature remains fragmented, with individual studies primarily addressing specific polymer families, optical performance, manufacturing technologies, or surface coatings rather than providing an integrated overview of ophthalmic lens materials. This systematic review critically examines the relationships between chemical structure and molecular architecture of ophthalmic lens polymers and their optical, mechanical, thermal, and processing properties. The literature published between 2000 and 2026 was searched in Web of Science, Scopus, ScienceDirect, and PubMed, following PRISMA 2020 guidelines, and 91 documents were included. Properties of poly(diethylene glycol bis(allyl carbonate)) (CR-39®), polycarbonate, poly(methyl methacrylate), poly(urethane-urea) (Trivex®), and high-refractive-index poly(thiourethane) systems are reported, with particular attention to refractive index, chromatic dispersion, impact resistance, durability, processability, and coating compatibility. Surface-engineering approaches, digital manufacturing, market developments, and environmental challenges associated with production waste and end-of-life management are also evaluated. The analysis identifies persistent trade-offs between optical performance, mechanical durability, manufacturing requirements, and recyclability, highlighting the need for high-index, low-dispersion polymers, durable or repairable coating systems, and viable recovery routes for crosslinked ophthalmic materials and lens-processing waste. Emerging opportunities for material recycling, recovery, and circular economy implementation are also critically evaluated. By integrating polymer chemistry, surface engineering, manufacturing, and sustainability within a single review, this work provides a comprehensive reference for researchers and industry professionals involved in the development of next-generation ophthalmic materials.