An automatic bar loader allows it to run continuously throughout the day, whereas the previous process required an operator to change the bar in a lathe or move a part to a mill every 45 minutes or so, he says. The turn-mill is also equipped with the automation features Mr. Parham says-the machine can be quickly reconfigured for different jobs. And thanks to the machine’s VDI tooling and an S-20 collet in the spindle nose-both of which are easy to change out, Mr. This has also improved part quality by helping to avoid the runout and tolerance stackup errors that can result from multiple re-fixturings. Many parts can now be machined complete in a single setup, and even those that can’t require significantly fewer machining steps, Mr.

I thought simply adding a mill step with live tooling for milling cross holes, shaft keys, slots and other features on the part before it comes off the machine would be enough to increase productivity.' 'I looked at a machining center with a Y axis and even a subspindle, but it was more complex than what I needed. 'I needed to increase productivity or increase capacity, and I didn’t want to buy another lathe and still have to move parts between a mill and a lathe,' Mr. Also, moving work previously done on the screw machine caused a bottleneck on the mills and lathes, which the shop used for both prototyping and an ever-increasing number of contract jobs. This process was far from ideal-moving parts from machine to machine was both labor and cost intensive, and multiple clampings increased the risk of error. After turning operations, ophthalmic components were moved to a mill for machining features such as wrench flats and cross holes. While the screw machine sat idle, the shop increasingly turned to its traditional lathes and mills. 'Still, we were led to believe that this particular machine would be easy to retool, to switch over, and it wasn’t as easy as presented.' 'We knew the screw machine was geared toward high-volume runs,' Mr. But lengthy setup and changeover times made this method inefficient for the low volumes characteristic of these jobs, too. To make up for the lost capacity and keep the screw machine busy, the company increasingly began to take on contract work. 'The main company that produces those devices has changed its way of doing things and is no longer making or supporting them.' 'Some of the products we were servicing at that time have gone away,' explains Tate Parham, director of engineering. However, within a few years, the company faced a precipitous drop in part volume on these jobs, and the screw machine became impractical. To efficiently handle large volumes of these components, the shop invested in a multi-axis screw machine. Many of these surgical instruments incorporate internal parts that are custom-built by the OEM, so replacements can’t be bought off-shelf. In addition to manufacturing work, the company is heavily involved in the service and repair of ophthalmic components. Niche Work If You Can Get It: A CNC Machine Shop Crafts Its Own Destiny As it is emulsified, the cataract is sucked through a small hole in the phaco tip. The tip vibrates between 20,000 and 40,000 times per second to emulsify the cataract. An example of one such component is a phaco tip, a small titanium needle that is inserted into a minute surgical incision in the eye. Components and accessories for phacoemulsification instruments, which doctors use to extract cataracts from patients’ eyes, comprise the bulk of the company’s products. DMG’s CTX 310 ECO V3 turn-mill with live tools and a C axis enabled the shop to operate with less labor and improved productivity and part quality in a lights-out environment.įounded in 1992, American Optisurgical focuses primarily on equipment for cataract eye surgery, although it also performs contract machining for a variety of industries to fill out extra capacity. When changes in the industry forced the company to alter its focus toward lower-quantity jobs, it sought to replace its multiple-machine process with a more efficient manufacturing method. American Optisurgical, a manufacturer of ophthalmic instruments in Lake Forest, California, is no exception. Achieving and maintaining maximum flexibility is often cited as a strategy employed by successful machine shops to stay ahead of the curve.

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