How Morrow uses 3D printing to redefine the design of smart eyewear

For Belgian start-up Morrow Eyewear, the challenge in developing electronic eyewear was not just technological but aesthetic. The company’s autofocal glasses, designed to seamlessly switch between near and distance vision at the touch of a button, necessitated a frame design that could discreetly conceal electronics without compromising comfort or style.

To achieve this balance, Morrow turned to Materialise, the Belgian 3D printing specialist, leveraging additive manufacturing to develop lightweight, customizable frames. “Success with smart glasses is not straightforward,” said Paul Marchal, Chief Executive Officer and co-founder of Morrow Eyewear. “People have to want to wear them. That means marrying aesthetic appeal with optical capability. We could meet this challenge by capitalizing on the design flexibility and physical performance offered by 3D printing.”

Launched in Belgium in 2021, Morrow’s autofocal glasses provide an alternative to traditional multifocals. Each frame integrates tunable liquid-crystal lenses that electronically adjust focal length. The 3D printed design ensures that the electronics are concealed within the frame while maintaining structural precision and lightweight comfort.

Scaling production

Working with Materialise enabled Morrow to prototype rapidly and transition toward scalable manufacturing. Marchal noted that the precision required for the product left no room for variation. “The bevel size and internal dimensions must be exact, or the assembly won’t function,” he said. “Materialise has turned color consistency and strength control into a science, which has been essential to our success.”

The company initially released a single frame design, but consumer feedback prompted the introduction of new styles. To diversify its portfolio without overextending production, Morrow collaborated with Belgian eyewear designer Bieke Hoet, who brought experience in 3D-printed fashion eyewear. The partnership resulted in more than 160 frame variations available through Morrow’s website.

Additive manufacturing has also allowed the company to produce frames on demand, avoiding excess inventory and material waste. “We don’t want to maintain a large stock,” Marchal said. “Shorter lead times let us keep learning what people want while minimizing waste and working capital. You don’t throw away half your stock at the end of a season.”

Born in ZEISS

Founded in 2016 by Marchal and Jelle De Smet, Morrow emerged from research at imec and Ghent University, where the team developed its liquid crystal lens technology. The company has since attracted significant investment, including more than €10 million ($10.3 million) from ZEISS Ventures in 2022. The round also included participation from New Science Ventures, imec.xpand, PMV, Tokai, and Qbic.

According to Gerrit Schulte, Head of ZEISS Ventures, the investment reflects growing interest in electrified eyewear beyond augmented and virtual reality applications. “The general electrification and functionalization of glasses and lenses is an area often overlooked. Solutions such as Morrow’s are key in enabling this,” he said.

In early 2024, Morrow expanded its European presence through a distribution partnership with Novacel Optical, providing access to markets in France and Switzerland. The agreement is expected to bring the company’s eProgressive autofocal technology to more than 30 million potential users in the two countries.

Marchal believes that continued development in materials and software tailored for eyewear will be critical. “Processes and materials must be developed specifically for eyewear, not simply applied to it,” he said. “That’s why partnerships with companies like Materialise are essential for long-term success.”