Medical Parts Manufacturing

   High Quality Standards Require

Quality Tooling Solutions

 Implant Screws - Dental Implants - Surgical Instruments & Devices

Medical devices and components are held to some of the highest quality specifications. Manufacturers face ever increasing demands for part production which drives them to seek out efficiency and precision from the tooling they use to achieve the quality standards and higher productivity.

It is our commitment to partner with customers and forge a path with technological insight with superior products and performance. By working closely with manufacturers to understand the machining issues they face we deliver a true tooling solution.

Design is Key to Success

Chipbreakers are designed to excel at the operation performed ensuring chip control - to curl and guide the chip away from the cutting area - which achieves excellent surface finish, improved tool life, and less machine down time. Meticulously ground inserts provide sharp cutting edges for consistency of part tolerances and low tool pressure.

17-4PH 900 - a chromium-copper precipitation hardened stainless steel - a hard alloy commonly used for applications requiring high strength and a moderate level of corrosion resistance. Machining conditions may vary with material hardness. ST4 grade provides excellent wear and adhesion resistance extending tool life and achieving stable machining of hard to cut materials. TFX insert is designed with a sharp cutting edge and chipbreaker that reduces cutting forces, controls chip evacuation, and  produces superior surface finish while allowing up to .197" (5.0mm) depth of cut.   

FRONT TURN OPERATION:

Teflon (PTFE) - polytetrafluoroethylene - is a thermoplastic with a low coefficient of friction, thermal and chemical resistance to solvents, acids, and bases. Proper machining techniques should be taken to eliminate dimensional changes during production runs. Burrs can be a problem because it is so soft. KM1 is an uncoated carbide grade. The inserts are manufactured with very sharp cutting edges for shearing the material and a mirror finish for excellent adhesion resistance. In this case study a .001"nose radius is applied. KM1 insert selection includes 0.0 radius options.

Front Turn | Back Turn | Cut-Off | Grooving | Threading.

FRONT TURN OPERATION:

Nitinol - a nickel and titanium alloy - is a shape memory alloy (SMA) which means it restores its original shape after deformation. Its biocompatibility and super-elasticity led to the creation of innovative medical devices which could not be manufactured with conventional materials. Originally applied to cardiovascular devices (stents, heart valves, guidewires) Nitinol use is expanding to devices for minimally invasive medical procedures. The inherent characteristics of this SMA material which is a blessing for doctors is a complication for manufacturers. Successfully machining Nitinol requires designing and developing special processes, testing out and fine tuning to prepare for production.  QM3 grade's superior wear resistance combined with an upsharp cutting edge was the answer for this tough application to increase productivity. ST4 is another go to grade, with proven successes, for machining SMA parts. 

FRONT TURNING OPERATION:

316 Stainless - Medical grade stainless - (chromium, nickel, molybdenum alloy of steel). The addition of molybdenum increases corrosion resistance against chloride ion solutions and improves high-temperature strength making it suitable for laboratory and medical environments. "GX" is a 3D style chipbreaker designed to curl and control the chip as it comes off the part during grooving and side turning operations.  No more tangled chips! The sharpness of the cutting edge ensures clean cutting for a superior surface finish.

GROOVING OPERATION:

Cut Duo (CTDP) tools accommodate large bar stock operations with part diameters ranging from .630" up to 1.340".  In this application, a 1/2inch holder which has a Max. Cut-off Dia. of .984" (25mm) is equipped with  a .079" (2.0mm) wide neutral DM4 grade insert.

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CUT-OFF OPERATION:

A2 - medium-carbon chromium alloy steel- is a member of the cold work tool steel. This steel latch shank part provides an economical solution used in the dental industry. These burs are softer, more flexible, and more resistant to chipping and breaking than carbide shank versions. The AC3 solid carbide end mill features edge sharpness to reduce cutting forces and leaves a remarkable surface finish.

MILLING OPERATION:

Traditional methods to generate socket features include:

1. End Milling - A small diameter endmill is driven by a high-speed spindle to create the feature. This method has some flexibility but, requires a high-speed spindle, involves complicated programs, and is a time-consuming process.
2. Broaching / Wobble broaching - A sequence of form tools is pushed through a drilled hole until the desired socket size is formed. In most cases, dedicated broaching machines are purchased for high production parts 

Shaper Duo tooling system comparison reveals its benefits which include:

• No need for high speed spindle  |  Simple programming code  |  Low cycle time  |  Inserts generate a range of socket sizes |  Low tool pressure  |  No special equipment to purchase   |  Consistent tolerances on parts

HEXAGON SOCKET OPERATION:

New size insert to the Hexagon Shaper line-up - generates Base AF of 12.7mm with an AF Range of 11 to 14mm 

Thread Whirling System for Multi-Lead Thread Forms & Specially Designed Threads

Parts Include: Bone screws and medical devices typically made from titanium alloys (Ti-6Al-4v ELI), and stainless steels (316). The capability to generate every aspect of a thread form in a SINGLE PASS with a whirling system is significant especially for medical screw manufacturing where threads are becoming more complex with multiple leads and high production quantities.

THREAD WHIRLING OPERATIONS:

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