Multi material Footbed flexible milling system

The result addresses the realization of a flexible milling system for the manufacturing of accommodative EVA based footbeds for orthopedic applications, based on the superimposition of multilayer freeform shaped parts, each milled on both sides in different EVA (ethyl vinyl acetate) densities. Such new milling system has been realized for automatic fast production of customized EVA footbeds, exploiting an approach based on two different simultaneously operating workposts: oA 5 axis milling workpost for the final milling and contouring of the single layer, as well as for the realization of the final superimposed product oA 3 axis milling workpost for the preparatory milling of the single layer, with appropriate surface roughness for subsequent gluing with other neighboring layers. Overall features of the system can be classified as follows: oSpindle type: electric with speed velocity regulation for milling control oTwo spindles for parallel piece processing oFrom a technical point of view, the machine runs without any cooling or lubrication systems, exploiting open LINUX RTAI control, and processing data from Rhinoceros CAM plugin.