July 2008 Edition

hot markets review: medical

Precision is the word in orthopedic implants

Device manufacturers gain solutions for accuracy, expediency

The Makino a61 is widely used in North America to make complex medical parts.

The Japanese call it seiki. Germans call it präzision. And to the English-speaking world, it’s precision.

Two medical device manufacturers recently found it was possible to achieve the highest obtainable precision. One was able to bypass expensive hand-finishing to save time, and the other saw its part cycles completed 40 percent faster.

All manufacturers strive for precision, but the word takes on new meaning for manufactured components of implantable medical devices. Even the slightest machining error or deviation from the design can have a severe impact. Such an error might not become evident for years after implantation, when the consequences are likely more serious to face.

For McMurray, PA-based FPD, a knee implant made of cobalt chromium-molybdenum alloy required time-consuming and expensive hand finishing. The part was especially challenging due to tight tolerances, sweeping geometries, and a fine surface finish.

All manufacturers strive for precision, but the word takes on new meaning for manufactured components of implantable medical devices. Even the slightest machining error or deviation from the design can have a severe impact.

Previous manufacturers used grinding to complete the part, but often struggled with the complex features. FPD felt the parts had to be milled to be consistent — again, where precision comes in.

This knee implant of cobalt chromium-molybdenum alloy is made by FPD.

After installing a Makino a61 horizontal machining center, FPD was on the road to precision. The machine was able to take complex geometries and demands for tight tolerances to finish the part so well that it didn’t need hand-finishing.

In addition, FPD was able to meet high production demands from its customer for the knee implant.

Another example is Brown Precision of Huntsville, AL. Brown was an aerospace, five-axis part producer, but wanted to apply its skill to the medical industry. Brown Precision knew a five-axis machine with accuracy in harder materials, such as 316 forged stainless steel, would be needed.

Again, the call went out for a Makino a61.

Since installing the a61, parts can now be finished in single setup. For instance, it’s a simple method to set up a forged stainless steel bone plate, which once took several setups to complete.

With the Makino a61, Brown Precision saw a 40 percent decrease in cycle time for the part. The company now owns several a61s, an a51, and other Makino machines for medical device and instrument manufacturing.

Makino

What do you think?
Will the information in this article increase efficiency or save time, money, or effort? Let us know by e-mail from our website at www.ToolingandProduction.com or e-mail the editor at dseeds@nelsonpub.com.