BostonSight Manufacturing Lab
PROSE Network providers directly access our proprietary FitConnect® platform to custom-design PROSE devices for their patients. FitConnect interfaces with our DAC high-precision lathes, which can cut complex prosthetic device configurations to precise tolerances. This sophisticated system enables BostonSight PROSE doctors anywhere to order customized devices for their patients and have them delivered the next day.
A Day in the Lab
Design
Device design specifications from a provider’s FitConnect account are pulled up in the lab and the order goes into process.
Diamond Tip Cutting
A round block of plastic is placed in the lathe, where a diamond tip begins cutting the diameter of the device and the base curve – the curve adjacent to the eye.
Radiuscope
The device’s base curve is measured using this vertical microscope to be sure it reflects the doctor’s prescription. The device is then moved to a blocker, where a blocking compound is applied to protect the base curve.
Back to the Lathe
The device is returned to the lathe, where the convex (outer) surface is cut. It is then moved to a small ultrasound unit, which removes the wax and cleans the device.
Lensometer
The device is placed in a lensometer, which checks the prescription and, specifically, the power, for accuracy. The device is then moved to a thickness gauge.
Tabletop Polisher
This hand-held unit is a silk wheel that is used to taper the edge of the device, which must be round and smooth for patient comfort. After polishing, we check the device under a microscope to ensure it has been tapered correctly and to check overall surface quality.
Plasma Treatment Unit
Each device is laser engraved with the order number, device number, and last four letters of the patient’s name. It is then moved to the plasma unit for a final 15-minute cleaning. The device surface is treated with ionized oxygen under pressure, which assures a comfortable surface for the patient.
Tangible-HydraPEG Station
After devices are plasma-treated, by request, they can receive a special coating treatment that increases wettability on the surface of the device which prevents protein buildup. Lenses are placed on a special tray with Tangible Hydra-PEG solution and then placed in a shaker. After treatment, devices are placed in a sealed case with Unique Ph solution.
Shipping and Pick Up Area
The device order, now completed, is checked out. Devices for patients at BostonSight Needham go to our drop-off area. Devices being shipped to PROSE Network Clinics are packaged and ready for delivery the following morning.
FDA Registered
BostonSight’s manufacturing lab is FDA and ISO registered, and maintains compliance to FDA 21 CFR Part 820 Quality System Regulation and ISO 13485:2016. The lab is also an authorized Finishing lab for Bausch & Lomb and Contamac materials.
