Machine builders are helping implant manufacturers to minimize secondary operations and boost productivity while meeting ever-tighter tolerances
By: Norbert Sparrow
SOURCING DIGEST
Laser profiling system offers precise cutting ability
A compact, high-precision laser system is specialised for the production of medical device components by means of cutting and profiling.
ES Technology Ltd (Kingston Bagpuize, UK;
www.estechnology.co.uk ) designed the ES-CUT150 system to be able to process metals with medical device applications, including stainless steels, titanium, aluminium, gold and silver. Capable of cutting material up to 2.0 mm thick, the 150-W pulsed YAG laser can be configured to produce a kerf as narrow as 18 µm. It provides precision cutting and profiling with minimal burr formation, operating at speeds to 35 mm/sec and with an accuracy of ±10 µm. The workpiece is moved under the fixed laser optics on a brushless-servomotor-driven x-y table with a 400 × 400-mm work envelope.
The cutting and profiling system is configured as a fully integrated stand-alone machine with a Class 1 enclosure to ensure safe operation. Setup is quick, involving importation of computer-aided-design (CAD) data for the part to be produced; the machine’s software accepts files in common CAD formats. The system manufacturer has developed a bespoke user interface for the PC-based control system.
Micromachining firm specialises in microfluidics
Offering a full design, prototyping and manufacturing service based on integrated micro-, nano- and biotechnology capabilities, a company catering to medical device and diagnostics manufacturers focuses primarily on the microfabrication of polymer microfluidic and microfeatured components. Its many in-house technologies enable MiniFAB (Aust) Pty Ltd (Scoresby, Australia; www.minifab.com.au ) to complete design and proof-of-principle activities quickly. The company selects the most appropriate polymer for an application on the basis of use requirements and the nature of the production process. When polymers alone do not provide the required functionality, it integrates patterned metals, adhesives, silicon dies and surface modifications.
Milling machine facilitates compound programming
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A milling machine is specialised for machining dental implants with angled geometries. The Deco 13a from
Tornos SA (Moutier, Switzerland;
www.tornos.ch ) features two special units and a software package that together enable users to keep up with growing component complexity in implantology. The machine offers milling subroutines to assist in compound programming. In such cases, the cutting tool’s machining path is calculated by contouring and interpolating the three linear axes, and it has variable mechanical incline units to mill the inclined cone section of the implant either from the bar through the guide bushing or, via a counterspindle, in back-operation mode. This configuration allows both roughing and finishing cycles to be completed, enabling complex implants to be machined without needing follow-up rework, even deburring. Back-operation machining in hidden time reduces overall cycle times. High-performance tool lubrication and chip removal are handled by either 15-bar sprinkler pumps or 120-bar high-pressure sprinkler pumps.
Milling operations are controlled by macros specific to implant manufacture, which govern milling of the angled cone with the joint perpendicular to either the part axis or the cone and elliptical milling by polar coordinates. These macros make possible simplified programming of the contour being milled, determine the feed rate and perform automatic calculations based on the implant cone’s incline.
PEEK rods offered in various configurations
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Curved stabilisation rods for spinal implant surgery can be machined from an advanced biocompatible polymer by a company that specialises in providing medical device manufacturers with precision-machined plastic components and assemblies. In fact, IDEX Health & Science (Oak Harbor, WA, USA; www.idex-hs.com ) expanded its core manufacturing capabilities in anticipation of demand for an alternative to titanium stabilisers. The company offers spine-device manufacturers a source for customised and packaged stabilising rods made of PEEK-Optima and produced in a variety of lengths, curvatures and diameters. The implantable components feature good mechanical performance and the capacity to withstand repeated sterilisation. They can be customised to exhibit the surface finish, degree of cleanliness and machining precision specified by the manufacturer. Finishing and packaging take place in a Class 10,000 cleanroom to ensure batch-to-batch consistency and sterility. The service provider is equipped to perform machining, heating, bending, marking, cleaning and packaging operations in accordance with exacting sterility and validation standards.
Micromilling unit configured for vertical machining
A five-axis computer-numerical controlled (CNC) micromilling machine has a small overall size of 1670 × 850 × 1740 mm and a working envelope about 100 mm square. The 5100 model offered by
Microlution Inc. (Chicago, IL, USA;
www.microlution-inc.com ) features a vertical machining configuration; linear-motor-driven acceleration of 3 G in the x-, y- and z-axes; trunnion-style fourth and fifth axes; a 60-pocket automatic tool changer and noncontact tool sensor; and an automation-friendly layout. Designed to provide high-performance machining of small components in a space- and cost-efficient package, the machine is capable of linear positioning accuracy within 1 µm, nanometre-level repeatability (±100 nm) and 0.1-µm resolution. Its a-axis tilt travel range is –17° to +107° and maximum speed is 41.7 rpm; c-axis rotary travel is 360° continuous and maximum speed is 83.3 rpm.
This vertical machine has a polymer concrete base with granite substructures. It supports several high-speed spindle options and accommodates a variety of palletised work-holding options. The CNC controller interprets standard Fanuc G-code.
