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Optician training face kits for EssilorLuxottica

Ten training kits for EssilorLuxottica's optician teams: three SLA printed faces at different pupillary distances, five coded eye clips and a stand, packed in a fitted case.

Client
EssilorLuxottica
Made for
Training opticians to measure and fit spectacles
Each kit
Three faces, five eye clips, a stand and a fitted case
Order
Ten kits, for Singapore and three teams overseas
Plan a training model (opens WhatsApp) Send a brief
Training kits, each in its own case
10
Faces, at PD 60, 64 and 68 mm
30
Eye clips, from 60 to 68 mm
50
A full case, with a handle to pull it
16.5 kg

What we brought

  1. What we can do

    Faces that teach a real measurement

    Each kit has three faces at pupillary distances of 60, 64 and 68 mm, and eye clips that swap between them, so trainees practise on more than one face.

  2. How we look after you

    Built on our earlier design

    We developed the kit from the fitting face we designed for the same client in 2023, so the new faces kept what already worked.

  3. What you get

    Packed to travel

    Everything sits in cut foam in a rolling hard case, with a covered tray for the eye clips, ready to ship to teams in other countries.

The build

How we built it

5 steps, from the brief to the finished piece. Pick a step to jump to it.

The brief

Step 1 of 5 · 14/07/2025

Faces
Three per kit, at PD 60, 64 and 68 mm
Eye clips
Five per kit, at 60, 62, 64, 66 and 68 mm
Order
Ten kits, so 30 faces and 50 eye clips
Our scope
Design, SLA printing, finishing, the case layout and packing for shipment

At Additive Inn, our 3D printing studio in Singapore, we made ten optician training kits for EssilorLuxottica. It was a repeat client: in 2023 we designed a fitting face for their optician training, and this order put that idea into a kit their trainers could carry from team to team.

Each kit holds three faces at different pupillary distances (PD), five eye clips that fit onto the faces, a telescopic stand and a hard case with a custom foam insert and a tray for the clips.

Design and prototyping

Step 2 of 5 · 23/12/2025

We started from the 2023 face design and modelled the faces over six revisions, checking each one against the pupillary distance it had to teach. In the end there were three faces, one for each PD. The eye clips attach with magnets, so a trainer can swap them between faces. We worked out which clips suit each face, so a trainee never pairs the two extremes:

  • Face PD 60: eye clips 60 or 62
  • Face PD 64: eye clips 62, 64 or 66
  • Face PD 68: eye clips 66 or 68

Each eye clip carries a small coded marking that the client chose, so trainers can tell the sizes apart while trainees cannot. We sampled the marking in several forms and shades before the client picked one.

  1. Revision 0

    The three printed faces.

    Photo +8 more

  2. Revision 0

    The first head models, a male and a female face, rendered from every side.

    Render +1 more

  3. Revision 1

    The heads cut down to face masks with ears, and the eye openings cut out.

    Render +1 more

  4. Revision 2

    Eye spacing measured at 68, 64 and 60 mm across three faces, and the nose reshaped.

    Render

  5. Revision 3

    The eyeballs placed for each face's PD, so no white gap shows when they sit right.

    Render

  6. Revision 4

    The female face scaled down to PD 60 mm, and the male face adjusted to PD 64 mm.

    Render

  7. Revision 5

    The three final faces at PD 60, 64 and 68 mm, each with its height and width.

    Render +1 more

  8. Eye clip, first marking

    A row of small marks on the clip, one more mark for each size.

    RenderPhoto +2 more

  9. Eye clip, final marking

    A short code in grey letters on the bridge, sampled in white, grey and black.

    Photo +1 more

Production

Step 3 of 5 · 27/01/2026

The faces were 3D printed by SLA in an ABS-like resin. We sprayed all 30 in a skin tone, then fitted the magnets for the eye clips. The eye clips were 3D printed with their codes, and we designed and printed a tray for each kit's five clips, with a cover that keeps them in place in transit.

All 30 faces, ready for their brows.

Finishing and packing

Step 4 of 5

The client compared painted brows with applied ones on a sample face and chose applied brows blended with powder, which we did on every face before a clear coat. Each face mounts on its telescopic stand by a ball head at the back.

We cut the foam so the three faces, the stand and the clip tray each have their own place in the case. A full case measures 69 x 55 x 39 cm and weighs about 16.5 kg, with a handle to pull it like a suitcase. We also filmed a short handling guide: how to move the case, what is inside, and how to put a face on its stand and take it off.

Applied brows, blended with powder.
The ball head mount at the back.
The back, with the magnet holes.
The telescopic stand.
A face on its stand.
With an eye clip fitted.
Eyes in, from the front.
The tray for the five eye clips.
The tray's cover.
The cover goes on the tray.
Placing the faces in the foam.
Every part in its own pocket.
The final layout of the case.
The case layout, on video.
From our handling guide.
Pulling the case like a suitcase.
The full case on its wheels.

The final build

Step 5 of 5 · 17/03/2026

All ten kits were packed, each case in its own carton. One went to the client's office in Singapore, six to its warehouse, and three were shipped to its teams in Indonesia, the Philippines and Vietnam.

From the left, the ear and brow.

The details

The sprayed skin tone, the brows and the shape of the nose, where spectacles rest.

The nose and lips, from below.

More product development

See all product development →
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