MLC Mill / Lathe Combo

Features

DAC MLC Mill/Lathe Combo with Options Click to enlarge

DAC MLC Mill/Lathe Combo with Options
Click to enlarge

 

DAC MLC Mill/Lathe Combo with OTT Option and Axis Location System

DAC MLC Mill/Lathe Combo with OTT Option and Axis Location System

 

  • High precision turning of contact and intraocular lenses and mold inserts
  • Polish-free haptic milling capability
  • Precision air-bearing slides
  • Linear motor axis drives
  • Sub-nanometer position resolution
  • Adaptive tooling positions
  • ASC (Automatic Sphericity Check) – rapid sub-micron sphere calibration
  • Oscillating Tool Technology (OTT) Option
  • Air-bearing turning spindle
  • High speed air-bearing milling spindle
  • Lens design graphics
  • DAC Script Language support for sphere, asphere and non-rotationally symmetric designs
  • Stable granite base available with passive or active vibration isolation systems
  • Custom features can be added upon request
  • Hi-speed servo system

Overview

The DAC MLC Mill/Lathe Combo is a member of the DAC ALM Family of Lathes.  The MLC is purposed  to provide a single machining station for the production of IOL lenses.  This unique ability ensures precision orientation of optics, haptics and other critical features of today’s specialty IOL designs, i.e. torics., multifocals, etc.

As with all of our ALM Family members, the MLC can be fit with a selection of options, including the OTT for torics and the Universal 1000 Autoloader for long-run production of stock or prescription lens designs.

 

Description

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IOL Haptic on DAC Mill Lathe Combo System

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Each axis is driven by linear motors with position feedback from linear encoders with 10 nanometer resolution. The technology of the air bearing slides eliminates air restrictor ports through the use of new technology. This technology provides ultra smooth motion that translates to ultra smooth surface finishes.

The lathe base is a 200 mm thick granite surface plate for accuracy and stability. The complete machine and electronics are housed in a single cabinet.

The Z axis is mounted directly to the granite and carries the spindle. The X slide is also mounted on the granite and precisely positioned at 90 degrees to the Z slide. This machine geometry assures the machining loads are well centered within the travel of the slides and that the spindle mounting is stiff and stable.

Multiple sets of tooling and a front surface gauging system are mounted on the X slide. The optional Oscillating Tool Technology (OTT) system can be added at the time of purchase or later to meet customer needs.

The Lathe spindle is a carefully balanced, air bearing high frequency unit with programmable speeds of 0 to 18,000 RPM.  An AC motor drives this spindle. A  DC motor with encoder feedback for the OTT option, provides torque at all speeds and the ability to synchronize with OTT tooling.

The Mill spindle is mounted on the X slide along with the standard roughing and finish tooling. This spindle is programmable from 25,000 to 160,000 RPM and can be used with both standard carbide or diamond tipped end mills.The collet holds 1/8” shank tools with a variety of diameters. Ultra-high resolution of the C axis (Lathe spindle) allows interpolation between X, Z and C axes to mill the plan view of intraocular lenses.

 

Operation

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The part to be turned may be held in the collet or blocked to an arbor for turning. Special collet arrangements are also available upon request. It is recommended that all turning be done with blocked parts and second side turning must be done on an arbor. The roughing natural diamond tool is used to remove the bulk of the material. As the controlled waviness finishing tool removes only a minimal amount of material, its edge (and life) is preserved.

All cuts are made by Z or X motion, or by ZX interpolation. Spheric and aspheric lenses can be turned with input from .cdl files and data tables. In addition, with the OTT option, toric IOLs can be designed, loaded and turned in the same manner as spheres and aspheres by simply adding the second radii to the data table. Because of the fine resolution (.010 micron) the surfaces require little or no polishing, depending on the material used and the manufacturer’s process.

Typical intraocular lens surfaces are turned in approximately 60 seconds, depending on geometry and material used. Milling the haptic design is done in 45 to 60 seconds depending on the complexity of the design.

 

Operator Interaction

Red BoxOperator Interaction

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“Menu” type queries, on the color monitor screen, guide the user quickly through machine set-up, calibration, alignment and tool replacement. DAC Script Language (DSL), which employs a subset of RS-274D machine language, is a high level programming language that is easily understood by the user and is included in each lathe.

If all lens design parameters are known, the user simply enters the appropriate numbers by use of the keyboard. The machine will calculate variables, such as junction thickness, after the entry of the basic design factors. A display of a lens cross section aids the user in the design process by graphically presenting the actual design. The machine’s computer automatically converts the lens design specifications in the machine language program necessary to machine the desired part.

Intraocular Lens Design Screen on DAC Mill Lathe Combo System

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DAC software presents the laboratory with a broad range of  options for the creation of lenses to meet the most demanding requirements. It can run as Windows or DOS based for easy interface with current DOS applications or other Windows-based lab equipment.

 

Control System

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The DAC Digital Motion Control (DMC) system is at the “heart” of all DAC Lathes. It is housed in the on-board computer, mounted with the servo amplifiers, in the base of the machine behind interlocked doors for easy access. Each axis is driven by a linear servo motor with linear encoder feedback.

Auxiliary functions such as actuating lights, vacuums, air blow-offs, autoloaders, etc., are controlled by outputs from the programmable logic control.

 

Tooling

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DAC MLC Mill/Lathe Combo with OTT Option and Axis Location System

DAC MLC Mill/Lathe Combo with OTT Option and Axis Location System

 

 

Both roughing and finishing tools are held in newly designed, micro-positioned holders that keep the tool parallel with spindle center. These robust tool holders are adjustable to accommodate a wide range of tool shank sizes.

The Oscillating Tool Technology (OTT) holds a diamond insert and is adjusted in the same vertical manner.

 

Software

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DAC International offers the industry’s most comprehensive lens manufacturing software — easy to use and easy to customize.  Full maintenance and calibration capability is built into our software, as well as on-line editing

Full details on DAC International Software

 

Options

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Please click on these links to see detailed descriptions of our available options:
ALM & MLC Options
Universal 1000 Autoloader

 

Specifications

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Slides:Air bearing slides are DC linear servo motor with linear encoder
feedback.  (Custom X-slide lengths are available as shown below.)
 XY
Type:Air-bearingAir-bearing
Travel:305 mm (12″)
356 mm (14″)
203 mm (8″)
Resolution:Sub-NanometerSub-Nanometer
Traverse rates:Maximum of 18 meters/min (720 IPM) 
Turning spindle:Precision air-bearing spindles, encoded or non-encoded, dependent on application 0 to 10,000 RPM
Mill spindle:Air-bearing, AC induction motor spindle, 15,000 to 160,000 RPM
Temperature controlled for operational stability.
Collets:Standard collet supplied with lathe – 12.7mm x 12.7mm (0.5″ x 0.5″) with dead length stop.  Specials supplied upon request.

 

Installation Data

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Power:208, 220, 230, 240 VAC, single phase, 50/60 Hz, 20 Amps
Air:7 SCFM @ 80 PSIG (9 m3/hr. @ 5.6 kg./cm2)
Air quality per ISO 8573.1 (2001), Class 2 or better
Clean, filtered, dry; supplied by user
Temperature:68 to 74 Degrees Fahrenheit (20 to 23 degrees Celsius)
Vacuum:User Furnished 58 mm (2.25″) Diameter Manifold
Minimum Floor Space:1,219 mm x 1,270 mm x 1,778 mm (48″ x 50″ x 70″)
Minimum Floor Weight:1,089 kg. (2,400 lbs.)
Minimum Shipping Weight:1,271 kg. (2,800 lbs.)

 

Videos

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Docs

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