Insole Milling Machine

The insole milling machine is used to produce insoles of various sizes and densities. This three-axis milling machine is designed for use by specialists in insoles or footwear manufacturers.

What is an Insole Milling Machine?

The insole milling machine is designed for manufacturing custom insoles in various sizes and densities. It features a three-axis milling system, allowing for precise and efficient production tailored to individual needs.

What is the Difference Between CNC Woodturning Machines and Insole Milling Machines?

Insole milling machines are designed specifically for working with EVA foam, which is used to create custom insoles. Unlike woodturning machines, which generate coarse wood shavings, these machines produce fine foam dust. This dust can penetrate the surfaces and mechanical grooves of the machine, potentially causing damage to moving parts.

To address this, insole milling machines are equipped with specialized sealing and components designed to protect the internal mechanisms from foam dust, ensuring durability even with frequent use. In contrast, CNC machines used for woodturning often use general-purpose components that are more susceptible to damage from dust, which can infiltrate motors and moving parts like carriages and ball screws, leading to potential malfunctions and reduced machine lifespan.

What is the Production Capacity of the Insole Milling Machine?

The insole milling machine is capable of producing 4 pairs of size 41 insoles per hour. Built with industrial-grade components, the machine can operate across three shifts per day, allowing it to produce up to 2,000 pairs of insoles per month.

What are the Prerequisites for Operating the Machine?

The machine requires a floor space of 1 meter by 1 meter. However, to accommodate maintenance needs, an additional 0.5 meters of space on each side is necessary, resulting in a total workshop area of 2 meters by 2 meters. Additionally, a suction device or bucket vacuum cleaner is needed to remove foam shavings, and a workbench is required for preparing the foam pieces before placing them in the machine.

What is the Difference Between an Industrial CNC Machine and a Clinical Machine?

Industrial CNC machines are designed for use in industrial workshop environments, typically requiring three-phase power, large dimensions, and no emphasis on compact design. They also generate high levels of noise and environmental pollution. In contrast, machines designed for clinical use operate on single-phase electrical power, are as compact as possible, and feature water-cooled spindles to minimize noise pollution. Additionally, clinical machines are fully enclosed to prevent environmental contamination, with built-in extraction systems for efficient removal of shavings.

Why Should We Use a Machine with a Closed-Loop Controller?

The core functionality of insole milling machines relies on the precise movements of motors. There are two general approaches to achieve this precision.

The first approach uses a stepper motor paired with a non-industrial controller, where the motor is simply instructed on the amount of rotation needed. It is assumed that the motor will execute this movement accurately and completely. This is known as an open-loop control system. While this method is basic and cost-effective, it lacks precision.

In the second approach, servo motors are used alongside an industrial-grade controller. In this system, the motor receives a command to move and simultaneously provides feedback to confirm whether it has executed the movement accurately. This feedback loop ensures that operations are completed with high precision. This closed-loop method is commonly employed in most industrial machines, leading to faster operation, increased machine longevity, and decreased operational wear.

Additionally, insoles produced by machines using closed-loop control are much more precise and reliable.

What does the machine’s maintenance service include?

Like all mechanical devices, insole milling machines require regular maintenance. This maintenance includes cleaning surfaces and mechanical components such as rails and guides, as well as lubricating and greasing the carriages and screws. Additionally, the machine’s water-cooling system also requires periodic inspection.

What is the Difference Between Water-Cooled and Air-Cooled Spindles?

The spindle is a component responsible for cutting material from the foam surface, operating at speeds exceeding 15,000 RPM. Due to these high speeds, it generates a significant amount of heat. There are two methods for cooling this component. The first method involves installing a fan on the spindle’s rotating shaft. However, at such high speeds, this fan produces a lot of noise, and since heat is transferred through the motor housing, the lifespan of rotating parts like bearings is significantly reduced. In the second method, the motor is placed within an enclosed housing, and water circulates within this housing via a pump. Because heat transfer in this method occurs directly through a thin wall, the temperature of moving parts like bearings remains low, greatly extending their lifespan.

How Does the Machine’s Configuration Affect Its Performance?

In the design of insole milling machines, the weight, body material, and mechanical structure are calculated based on the machine’s mechanical frequency to minimize vibrations. Due to the high speed of the spindle in this machine, an aluminum body is required, which must be precisely machined to dampen vibrations and reduce overall machine shake. Reducing vibrations not only improves the quality of the insoles produced but also significantly extends the machine’s lifespan.

How is Data from the Pressure and 3D Scanners Converted into G-Code?

Specialists analyze the data collected from foot pressure and 3D scanners, along with clinical examinations, to identify and diagnose abnormalities related to the feet and posture. Based on these findings, they determine the type of insole needed and specify the parameters to be included. The main parameters include different wedges around the foot, in the forefoot or rearfoot area, the height of the arch, the placement and height of various pads, the type of heel, the height of the heel walls, and the material used for the insole.

After this assessment, the insole design can be created using the PT-Insole Design software. The software is pre-configured with the settings required for the PT-Mill machine and automatically generates the necessary G-code for producing the insoles.

What Materials Are Used for Manufacturing Insoles?

Insoles are typically made from EVA foam. The hardness of this foam can vary significantly, and specific levels of softness are required for different abnormalities or conditions.

Advanced design software, such as PT-Insole Design, allows for the inclusion of multiple layers of foam with varying thicknesses and softness. The software specifies the amount and type of foam needed for each part of the insole during the design process. It also enables simulation of pressure on different areas of the insole, allowing specialists to verify the effectiveness of the design before the insole is manufactured.

What are the Working Dimensions of the Insole Milling Machine?

The PT-Mill is designed for use in clinical settings, so its dimensions are optimized to fit through standard apartment doors and elevators. The insole milling machine’s working area is sized to accommodate the production of one pair of insoles at a time. The worktable dimensions are 40 cm by 40 cm with a height of 12 cm, which is suitable for creating insoles with appropriate thickness and lift.