Medical Device Link.

Originally Published EMDM May 2003

ENGINEERING INSIGHT

A fabricator of implant components reports an 80% productivity gain

Using DP Technology’s Esprit CAM system, U. Klein GmbH was able to reduce CNC programming time for the machining of a complex implantable part from one week to five hours. Esprit software automatically generates the G code that is required to program the CNC machines. It also enables users to import models directly from a customer’s CAD software.

Conventional CNC programming methods can delay production and increase a product’s time to market. In today’s competitive environment, that was not acceptable to U. Klein GmbH (St. Ingbert, Germany), a contract manufacturer that specializes in producing components for medical OEMs. The firm recently switched to a CAM system, which has enabled it to slash programming time for complex parts by as much as 80%. “The time savings have been fantastic,” says CNC programmer Ralf Merz. “We reduced the programming time for a medical knee implant from one week to five hours.” Not only has the switch proved to be more time efficient, but the new system has increased accuracy and control over the machining process, thereby improving the quality of the finished product.

“In the past, we programmed our CNC machining centers by developing macros that performed common machining functions,” says Merz. “Then we built our programs using these macros. This worked well with basic components, but was very time-consuming with the complicated contours that the medical device industry has begun to use in recent years,” he adds. On several occasions, Merz notes, the company had to refrain from giving customers a price quote because engineers were unable to write a G code, or CNC program, for the job within a reasonable time frame. U. Klein had little choice but to upgrade its programming capabilities, he adds.

In its search for a CAM system that would meet all its requirements, U. Klein turned to DP Technology (Montpellier, France). “We selected the Esprit CAM system from DP Technology because it provides a solid-modelling environment that is capable of defining the most complex geometry and an open architecture that offers enormous flexibility,” Merz explains.

“Esprit’s advanced hybrid solid-modelling kernel enables U. Klein to import files directly from a customer’s CAD software intact, while the program’s universal postprocessor automatically produces flawless G code for the CNC machines,” says DP Technology vice president Chuck Matthews.

U. Klein had been designing parts in Solid Edge based on sketches or blueprints provided by the customer. Now the company is able to import the Solid Edge files directly into Esprit, with all of the solid faces trimmed and in the proper orientation. Merz explains that there are no limits to the shapes that can be designed using the system. The CAD software automatically detects and corrects gaps and duplicates in the geometry during the import. The system’s automatic editing process reduces programming time by eliminating the need to manually define the geometry of a certain part. The operator can print out a simulated image for customer approval and then specify the tools to be used and the cutting speeds and feeds. Because most of the parts are machined from solid blocks of metal, Merz often uses Esprit’s automatic roughing capabilities to produce tool paths that quickly remove the bulk of the material from the workpiece. He then defines the finishing cuts, and simulates the machining operations on the screen to ensure that the machined part matches the design. Within a few hours, the G code can be created to produce the part.

“This new CAM system has helped our company to compete in a challenging market by allowing us to program any part, in considerably less time than our competitors require,” Merz concludes. “Esprit enables U. Klein to accomplish its primary goal as a contract shop that helps customers bring new ideas to market faster than the competition.” 

To learn more about these products, circle #7 for U. Klein GmbH or #8 for DP Technology on the Reader Service Card, or go to RequestLink at www.devicelink.com/emdm. 

Copyright ©2003 European Medical Device Manufacturer