SOURCING DIGEST
Five-axis machining centre
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Accuracy of machining on the workpiece can be expected to be 1 µm or better when a CNC machining centre designed with hydrostatic guideway drives is used. The Pyramid Nano from Kern Micro- und Feinwerktechnik GmbH & Co. KG (Murnau-Westried, Germany; www.kern-microtechnik.com) exhibits positioning scatter according to VDI/DGQ 3441 of ±0.3 µm. This high-precision, high-accuracy performance is achievable throughout the machine’s x-y work envelope of 500 × 500 mm. The machine bed features symmetrical construction from the manufacturer’s own Armorith material. The thermally stable and vibration-dampening base helps the machine to achieve high precision levels.
The manufacturer has employed hydrostatic rather than linear drives in the machine design because the former do not create a whipping cogging effect. Hydrostatic guideways lift the machine table 18 µm, thus there are no metal-to-metal contacts or wearing parts. Because the oil in each guideway is temperature controlled, no variation in accuracy among axes will occur, even if one axis is being moved faster and further than another. The hydrostatic guideways allow machined components to be given a good surface finish. This machine comes with either a 6.4-kW HSK-25 spindle running at 500 to 50000 rpm or an 11-kW HSK-40 spindle offering a speed range of 200–36000 rpm. The spindle is housed in the temperature-controlled guideway system of the z-axis. A two-axis torque-drive trunnion table can be equipped with a choice of chucks that provide accurate workpiece positioning and a basis for automated workpiece changing. A tool magazine with up to 95 positions and an integrated workpiece changer with 20 positions or external changers with pallets as large as 280 × 280 mm are available to automate operations.
CNC honing machine
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A modular honing machine series is engineered to be scalable from a basic, single-spindle machine to a fully automated multispindle unit with robotic part handling, postprocess air gauging, and statistical process control (SPC) and tooling flexibility. Sunnen Products Co. (St. Louis, MO, USA; www.sunnen.com) has designed the SV-1000 vertical honing machine to size and finish bores in 3–65-mm-diam parts to accuracies as fine as 0.25 µm. Suited for machining medical device components in medium to high volumes, the CNC series can perform conventional and single-pass honing with any tool in the manufacturer’s line. A servo-controlled stroking drive responds smoothly to motion profiles generated by the control, and a load-sensing tool-feed system minimizes processing time by sensing where and how much to hone the bore.
The basic module, designed to accommodate future automation, is available with a fixed tooling plate or servo rotary table. An industrial PC-based control provides an easy support path. Automated versions of the machine can be specified with the rotary table or linear parts transfer, integrated parts-handling systems, and as many as four spindles. Air gauging to provide closed-loop control of bore size and geometry, together with downloadable SPC data and feedback control, can be added for unattended cellular processing and to control hole size to the 0.25-µm level of accuracy.
The machine’s vertical design conserves floor space. With a high-torque belt-driven spindle rated at 7.5 kW, the honing unit can take on a range of sizing and finishing projects at processing speeds of 100–4000 rpm. Optional accessories can be supplied to make a custom processing cell suited to a variety of application requirements.
Laser processing system
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A laser system is suited for fine cutting operations in the manufacture of medical and electronic devices. The fully integrated StarCut Universal system from Rofin/Baasel Lasertech (Starnberg, Germany; www.rofin.com), which is available with a choice of solid-state laser sources of the StarCut generation, features a work envelope measuring 600 × 300 × 200 mm as well as three high-precision CNC axes. This standard machine provides flexibility, as well as 50-µm precision, for fine cutting. An optional rotary axis adds capability, enabling the system to produce complex 3-D geometries.
The system’s CNC controller and software are compatible with all major computer-aided design system formats and thus facilitate setup and program changeover. The personal-computer-based control system is designed to be easy to operate. The complete integrated system includes motion stages together with the laser source and control system.
Providing good beam quality and high cutting speeds, the available laser sources are characterized by pulse-to-pulse stability and come with power outputs up to 300 W and frequencies up to 3000 Hz. The established StarCut 18, for example, has a power range of 7–25 W and achieves kerf widths of 18–20 µm. An additional option is the new StarCut 12fm, a 12-W fundamental-mode laser whose pulse characteristics enable it to cut fine tube or plate material up to 1.0-mm thick with a kerf width as fine as 15 µm.
Work-holding vises
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A line of 4-in.-capacity (101-mm) vises designed to hold small parts on small-scale machining centres includes manual and hydraulic models. Offered by Kurt Manufacturing Co. (Minneapolis, MN, USA; www.kurtworkholding.com), the HDL 4-in. work-holding units are two-station long vises that provide clamping performance repeatable to 0.0002 in. (0.0051 mm). Each station opens to a full 4 in. (10.16 cm) using the manufacturer’s standard hard-jaw system. Designed with an 80000-psi ductile-iron body and precision-machined steel components, the vises provide strength, rigidity and long-term accuracy while absorbing the vibration generated by machining.
The manual vise features an adjustable-preload design. This minimizes the preload range so that few turns of the handle are necessary to open or close the vise. Its holding block allows parts of dissimilar size to be clamped and provides preloading ability in the front or back jaw. By maximizing the number of parts fixed in the work envelope, the vise’s multiple-part work-holding capability optimizes spindle utilization, reduces the time devoted to tool changes and minimizes machine travel from part to part. A kit is available to convert the vise to hydraulic operation.
Metal injection moulding
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Small metal parts with complex shapes or intricate details that may challenge the capabilities of machining processes can be moulded from powdered stainless steel and other metals by a contract specialist in metal injection moulding. The more complex the shape, says Metal Injection Mouldings Ltd. (Altrincham, UK; www.metalinjection.co.uk), the more economically advantageous the moulding process will be compared with other metal forming techniques. The consistent, efficient process is suitable for disposable parts as well as any metal component that is difficult to machine from solid stock. It accommodates close-tolerance requirements and can result in fine surface finishes.
Part features that can be moulded from metal include fine gear teeth, serrations, lettering and nonround holes. Blind holes are as easy to produce as through holes, and internal or external threads can be included in the mould. Nickel- and cobalt-based alloys, carbon steels, tool steels and magnetic irons, as well as stainless steel are used to produce moulded medical and surgical components, hand tools and precision equipment weighing up to 100 g.
Contract machining
A company with know-how and experience in precision engineering specializes in the manufacture of high-precision medical technology components and devices on a contract basis. Providing systematic quality management throughout the production process until final delivery, Tschudin + Heid AG (Waldenburg, Switzerland; www.tschudinheid.ch) offers comprehensive services. It uses up-to-date CNC equipment for all processes involved in manufacturing user-friendly implants and instruments for medical specialists, including products such as bone screws and reconstruction and trauma plates machined from titanium. The contractor emphasizes flexibility, reliability, and timely delivery as central to its mission.
The service portfolio begins with the development stage, which encompasses feasibility studies and design. The company’s development department has a highly modern infrastructure. In producing bone screws, the production department uses advanced, automated CNC single-spindle screw machines to accurately cut threads and perform complex head machining in a single operation.
Micromilling machine
A three-axis CNC milling machine has been designed specifically for the manufacture of demanding microsize parts. Developed by Microlution Inc. (Chicago, IL, USA; www.microlution-inc.com), the 363-S micromilling machine offers proven 2-µm positioning accuracy, 50-nm resolution, and 200-nm repeatability throughout its 63 mm of travel in the x, y, and z dimensions. Thus, the easy-to-use machine is capable of producing complete microscale features that demand tight absolute tolerances. High-resolution, high-accuracy Heidenhain optical linear encoders mounted to precision-ground granite substructures under the x, y and z stages support this micromilling performance. The encoders’ short grating periods help minimize the magnitude of short-period errors.
Occupying a footprint of approximately 600 × 600 mm and having modest utility requirements, the machine can be installed in the laboratory or office as well as on the shop floor. It features a 36-pocket automatic tool changer supporting tools ranging from 0.002 to 0.125 in. (0.051 to 3.175 mm) in diameter; a ball-and-vee kinematic mounting system for both the workpiece and the spindle that allows re-placement of either, following removal, at a submicron level of repeatability; and an integrated controller that provides flexible CNC machine operation using standard G and M codes. Custom interface circuitry facilitates access to digital and analogue input/output, limit inputs, and flag inputs.
The combination of high-performance encoders with high-specific-force linear motors allows high-bandwidth tuning. This feature and the fact that the ac linear motors used throughout the machine produce zero cogging torque maximize the dynamic performance of the stages for good contouring results in the machining of various materials, including metals, plastics, glass, and ceramics.
Investment casting
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The economical investment casting process, which operates on the lost-wax principle, offers a wider design freedom than many other methods of metal forming. Castings produced by P.I. Castings Ltd (Altrincham, UK; www.pi-castings.co.uk) for medical devices, surgical instruments, hospital equipment and dental components have close tolerances and near-net shapes, and require little machining to become finished components. The process is suitable for manufacturing parts in complex shapes from stainless steels, nickel and cobalt alloys, aluminium and most other metals. Its capabilities include undercut sections, fine teeth, holes with flats, intricate details and smooth surfaces.
Owing to low tooling costs and short setup times, the service provider can produce low quantities of parts economically. The investment casting process is also suitable for the production of rapid prototypes; metal parts are created from models generated via computer-aided design, without any need for conventional tooling. The company uses all rapid prototyping techniques to make one-off investment castings or preproduction runs of parts. It has its own 3-D printer for producing wax models. In addition, its extensive facilities include equipment for X-ray and dye-penetrant inspection, mechanical testing, spectrographic analysis, heat treatment and machining.
Miniature components
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Highly miniaturized components that the manufacturer calls building blocks for innovative minimally invasive medical devices can be produced by means of a trademarked proprietary additive-layer manufacturing technology. Microfabrica Inc. (Van Nuys, CA, USA; www.microfabrica.com) has used its flexible EFAB technology to make med-tech components such as water-powered turbines just over 1-mm in diameter that spin at 120000 rpm; millimetre-scale tissue and tube expanders; ultraflexible metal fabric made of microlinks and similar to chain mail; microneedles; miniature ratchets, hinges, slides and springs; and multilumen metal shapes. Originally applied to the manufacture of computer chips, the technology offers accuracy on the order of 1 µm.
The manufacturing technique involves the deposition of as many as dozens of precisely defined layers of metal, and achieves part features and tolerances measured in microns. It can be used to produce fully assembled devices with dimensions in the centimetres or millimetres. The developer reports that companies employing the technology are planning on commercializing products for a dozen disparate medical specialities at this time.
EFAB can provide several productivity advantages. It is, for example, directly scalable from prototype to volume production. In addition, it offers the capability to manufacture mechanisms with numerous moving parts without any need for assembly. The technique can produce parts with greater complexity and smaller features, often more accurately and economically, than is possible via machining, injection moulding and electrical-discharge machining. Unlike laser and photochemical machining and stamping, it generates no artifacts.
Orthopaedic devices
A total-supply-chain contract manufacturer specialises in the design and production of orthopaedic implants and instruments. Innovative technologies and products for medical and dental devices, spinal and extremity orthopaedics, trauma surgery, reconstructive surgery, orthobiologics and sports medicine are developed by Orchid Orthopedic Solutions LLC (Holt, Michigan, USA; www.orchid-orthopedics.com), a company with 10 divisions variously specialised in design, forging, machining, plastics processing and coating application. All parts of the enterprise are certified to ISO 13485:2003.
The range of services available from the design division includes comprehensive concept development, feasibility study, design, prototyping, qualification testing, design for manufacture and small-scale and pilot manufacturing. Working with titanium, cobalt chromium, molybdenum, stainless steel and zirconium, the forging division provides engineering, net and near-net component forging, full machining capabilities and project management. Four vertically integrated machining divisions perform turning, milling, grinding and electricaldischarge machining, together with special processing such as laser welding and etching, gun drilling, microdeburring and diamond coating.
Offering experience with a range of medical-grade plastics, the plastics division performs CNC machining, injection moulding, cleaning, assembly and primary and secondary packaging, in portable Class 10000 cleanrooms as appropriate. Finally, the three coating divisions surface-treat joint, spinal and dental implants with hydroxyapatite, titanium plasma spray, resorbable blast media and composite coatings, and can provide custom coating technologies.
Hip joint test system
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Among the systems available for the dynamic and static in vitro testing of hip endoprostheses and their components is a servo-hydraulic testing machine for performing the dynamic endurance test specified in ISO 7206. The HC 10 testing machine from Zwick GmbH & Co. KG (Ulm, Germany; www.zwick.de) simulates the dynamic stress at the shaft of the prosthetic hip joint during walking. By placing axial alternating loads on the shaft, it tests the endurance of the shaft over its expected lifetime The standard specifies that the test be performed with a maximum frequency of 30 Hz, but the test cylinder is designed to provide frequencies up to 100 Hz to accommodate additional applications.
A low-noise hydraulic power pack integrated into the system’s base, which produces sound at a level below 60 dBa, saves space and makes the machine compatible with the laboratory environment. Another noteworthy machine feature is the lateral differential bearing mounted directly into the test actuator. This bearing compensates the lateral movements between the femoral ball and the acetabular cup of the joint during gait simulation to ensure the correct physiological relation of femoral stem to acetabular cup and yield precise axial measurement without any shear-force distortion.
An additional testing actuator constitutes the torsion axis for the test spelled out in ISO 7206-08, where superimposed compression and torsion stress on the hip joint make possible simulation of a different set of movement sequences and stress scenarios. Also, an ambient bath with a temperature control unit is supplied for purposes of in vivo simulation in saline solution at approximately 37°C. The software testXpert II that supports this dynamic testing regimen includes a user administration system with documentation according to the requirements in the US FDA 21 CFR Part 11 regulation.
Gang tool lathe
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Short cycle times and high precision are available to users of a gang tool lathe that features a c-axis spindle as standard, a polymer composite base for vibration reduction, and precision components for fast and accurate turning of small parts. The Prodigy GT-27 single-spindle lathe from SNK-Europe (Göppingen-Ursemwang, Germany; www.snk-europe.de) uses three axes of motion that can be commanded in absolute or incremental modes. Its spindle, which can reach a speed of 6000 rpm, allows for indexing, positioning and advanced functions such as interpolation and polar coordinate milling. The heavy weight and the thermal-distortion-resistant polymer base of lathe are designed for high rigidity and accuracy.
The incorporation of non-heat-generating collet closers, the absence of a turret and full c-axis indexed positioning enable the machine to perform with precision and versatility. Being able to index in 0.01° increments, the lathe lets users employ live tooling for side drilling and milling in both simple and complex operations. The tool is suited for primary and secondary machining in medical device applications working with bar stock up to 27 mm diam. It is supplied with a GE Fanuc controller for ease of operation and responsive performance.
Blast-finishing cabinet
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A specialist finishing equipment manufacturer’s product line includes a stainless-steel blast cabinet engineered particularly for medical product manufacturing, laboratory applications and other uses in which ferrous contamination would be detrimental. Guyson International Ltd. (Skipton, UK; www.guyson.co.uk) has been adapting its manual blast cabinets so that manufacturers can use them to prepare implant surfaces for coating and bonding and impart to medical instruments a glint-free cosmetic finish, but now it offers the Mediblast 1400 cabinet as a standard unit that can cope with the vast majority of manual medical blast finishing requirements. This cabinet is made from Type 316L stainless steel and is equipped with a Model 900 blast gun that features a polyurethane body and stainless air-control jet.
Internal dimensions of the continuously welded blast chamber are 815 × 560 × 591 mm. Overall machine height is 1527 mm. A full-depth hinged door facilitates access to the illuminated chamber. Operated by foot pedal, the blast gun can be held in the hand or kept on an adjustable support within the chamber so that the hands are free for component manipulation.
The surface treatment system is supplied with a range of types and grades of blast media. It is supplied with a dust collector that efficiently filters the work environment to allow clear viewing of the component during blasting.
Machining centres
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A pair of precision machining centres are built for optimum accuracy and speed in the machining of small and midsize parts, dies and moulds. The latest additions to the YBM series available from Yasda Precision Tools (Düsseldorf, Germany; www.yasda.com), the YBM7T and YBM8T centres, use twin ball screws and hybrid box-type guideways positioned on either side of the spindle head of each machine’s y-axis to maximise stability and machining accuracy. They offer high rigidity and vibration damping capability against the forces generated by high-speed machining in the x-, y-, and z-axes.
Furthermore, a spindle-bearing preload self-adjustment system provides a large preload during low-speed operation for heavy cutting and adjusts the preload in accordance with the heat generated by the higher-speed spindle. A diaphragm coupling that coaxially connects the spindle cartridge and motor is designed to ensure accurate spindle rotation at full rotational speed. To support high-speed performance in the YBM7T, the company has integrated into the design scissors-type pallet forks that rotate quickly on a direct turn system.
An inverter control system for the heat exchanger and hydraulic unit minimises thermal effects and energy consumption for these machines. In addition, a thermal distortion stabilising system and coolant temperature control system, both available as options, can further reduce internal and external thermal distortion of the machine structure and thus help maximise precision. The machines are controlled by MiPS, an advanced version of the earlier Mascot mini machine control system.
Sliding-head lathe
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A 12-axis CNC sliding-headstock mill-turning centre offers the ability to significantly reduce cycle times for one-hit machining of complex components measuring up to 20 mm in diameter. Available from Star Micronics GB Ltd (Melbourne, UK; www.stargb.net), the ECAS-20T has three independent turrets with eight live stations each, and each station can accept up to three tools. The two turrets mounted above the spindle’s centre line are positioned in the x and y axes, and the lower turret on the left offers the added feature of an axis in z. The two left-hand turrets serving the main spindle allow complex machining, including turning, milling, cross-hole drilling, and deep-hole drilling with high-pressure coolant. The right-hand tool turret provides for rear-end working.
Similar in design to a previous model with a 32-mm bar capacity, this high-end machine is ergonomically enhanced for better access, visibility and operability. Identical 10000-rpm motors drive the main and counter spindles, each of which has a c-axis. The headstock stroke is 350 mm, allowing parts up to that length to be produced in a single setup. In all controlled axes, the rapid feed rate is 30 m/min.
The lathe features an advanced motion control system that enables programming of simple turning operations to be carried out off-line to facilitate rapid process cycles. Conventional computer numerical control can be used for more-complex operations. For parts involving a combination of simple and complex machining, the cycle can be defined by both motion control programming and traditional programming in ISO. Machining from a part program is entirely electronically controlled for tight synchronisation between axis movements.
Contract machining
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A contract manufacturing partner specializing in orthopaedic and dental components such as screws, plates, and abutments provides clients with a comprehensive range of services extending from the design stage to delivery of a sterile packaged device. Consisting of a group of medical technology companies in Denmark and Sweden, Elos Medical AB (Timmersdala, Sweden; www.elosmedical.se) also manufactures bone-anchored hearing aids, delivery system components for diabetes treatment, and implants and instruments for neurosurgery, cardiac surgery, and cancer treatment. The companies are certified according to ISO 13485:2003, ISO 9001:2000 and ISO 14001:2004 and registered with US FDA, and can produce orthopaedic and dental products up to Class IIb with the CE mark.
To minimize time to market, the company’s designers work in close collaboration with the client and the clinics that evaluate the products. An in-house prototype workshop and test laboratory further accelerate this stage of development. For production and quality control, the manufacturing facilities are equipped with CNC lathes and mills, optical and detecting measuring instruments, and a variety of washing systems, including ultrasound and spray cleaning equipment. All products are documented for full traceability. ISO Class 7 and Class 5 cleanrooms for packaging sterile products are available, as are facilities for sterilizing products after packaging by means of steam and beta and gamma irradiation.
Finally, to keep the customer’s chain of suppliers as short as possible, the company can perform assembly, functional tests, packaging and labelling in cleanrooms of the appropriate classification, and provides final packaging for delivery to clinics and hospitals. It offers a vendor-managed inventory system to minimize lead times and stockkeeping burdens for the customer.
In-process gauging system
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A hard-wired touch probing system is designed to allow users of sliding-head CNC lathes to measure turned and milled features on every component just after it has been machined, while it is still in the counterspindle and before ejection. Based on the type 41.00 probe, the system, developed by m&h Inprocess Messtechnik (Waldburg, Germany; www.mh-inprocess.com), is believed to be the first real-time, in-process quality control system for performing 100% inspection of critical dimensions on sliding-head lathes. Employing a fixed probe mounted on the headstock, the gauging arrangement is suitable also for use on fixed-head, bar-fed, twin-spindle turning machines on which the counterspindle can move in the x- and z-axes.
This in-process system can improve productivity for manufacturers and subcontractors that specialise in unattended close-tolerance machining of medium-sized to large batches of components. Particularly when hard material is being cut, regular on-machine inspection helps in monitoring insert wear and allows tool offsets to be updated automatically. Besides preventing out-of-tolerance cutting, the system enables a cutter to be used until it fails rather than be replaced arbitrarily after a certain number of components have been produced, thus potentially saving on tooling costs.
The probe can measure part diameters so that tolerances down to plus or minus a few microns can be maintained. Measurement of an outside diameter takes typically 1 second. However, even when additional critical dimensions are included in the inspection cycle, no production time is lost, because the inspection routine runs concurrently with the main spindle operations. As part of the gauging system package, the firm supplies the interfaces and writes a measuring program to check each type of component being manufactured.
Micromechanical systems
Custom micromechanical systems for medical technology applications are the speciality of a supplier serving as a partner to customers from the product concept stage through market launch of the packaged medical device. Cendres+Métaux S.A. (Biel-Bienne, Switzerland; www.cmsa.ch/medical) produces high-precision components for dental implantology, traumatology, otolaryngology, cardiology, and neurology applications, in small batches or large-scale production volumes. It handles projects involving products in the US FDA risk Classes I, II, and III.
The company uses up-to-date 3-D measuring machines to monitor and record component geometry for statistical process control of tolerances. It inspects dimensions, materials, surfaces and packaging to ensure that products consistently conform to a high quality standard and satisfy customer requirements. Also, it guarantees the traceability of all products and materials. The service provider is certified to ISO 9001, ISO 13485 and ISO 14001 and is US FDA registered.
Acting as a general contractor, the company offers a single source for engineering, manufacturing and packaging, as well as in-house materials testing in metallurgy and analytical laboratories accredited in accordance with ISO/IEC 17025. It offers its partners expert advice in developing custom component manufacturing processes.
Turned microparts
A contract manufacturer that specializes in precision turning can produce microparts for medical and dental applications. In addition to series production capabilities, Polydec S.A. (Biel-Bienne, Switzerland; www.polydec.ch) offers services as a development partner, including customer-specific engineering, feasibility studies, prototype construction, and materials research. The company’s plant for automated turning of micromechanical components is set up to be able to deliver the highest precision over large production runs and to produce parts that are extremely small and highly complex. The latter work is performed using computer numerically controlled lathes with movable spindles.
The principal machining method the company employs is turning, which can produce many types of rotational solids. Other processing methods are also available to enhance parts for specific applications. Milling heads with complex geometries are used in polygonal turning to produce polygonal shapes in workpieces without interrupting the rotational processing. Knurling equipment uses great hydraulic pressure to roll useful structures into the workpiece surface prior to further processing or assembly. The company is also equipped to harden finished workpieces by means of heat treatment and to remove burrs from and smooth the surfaces of machined and hardened parts. Quality assurance system certifications to ISO 9001 and ISO/TS 16949 attest to consistent high levels of performance and efficiency in development, management, and production processes.
Torsion testing system
A precision mechanical test system for electromechanical torsion is designed specifically to meet the needs of orthopaedic and medical device developers. The tabletop Bionix EM Torsion system from MTS Systems Corp. (Eden Prairie, Minnesota, USA; www.mts.com) integrates a compact electromechanical load frame, advanced digital controls and TestWorks application software to provide safe, easy and reliable testing of biomedical components and tools subject to torque loading. The system is engineered to apply low-force monotonic and multicycle torsion accurately, optionally in conjunction with a static axial load, within a load range suitable for testing orthopaedic bone screws and surgical tools and medical device components such as tubing, catheters, torsion springs and lead wires for their durability under conditions of twisting and insertion.
The system’s high-performance components include a slotless AC servomotor, digital sine-drive amplifier and high-accuracy direct drive for applying torque to specimens precisely. A large test space is user-friendly and designed to accommodate changing needs, and an ergonomically designed remote handset facilitates specimen preparation. The axial loading system located at a remove from the test space ensures safe application of loads and allows the system to be switched from tension to compression test modes without disturbing the test setup. Optional load cells and displacement measurement encoders provide accurate monitoring, data acquisition and readout of static axial loads and displacements.
Featuring a suite of prepackaged torsion test methods to help users meet the requirements of established orthopaedic and medical device testing standards, the easy-to-use application software provides flexible test definition, strong data acquisition capability and analysis and reporting functions. It fully supports manufacturers’ efforts in pursuing device approval as well as generating test results that sustain production operations and continuing product development activities.
Electropolishing system
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Manufacturers of high-volume metallic devices and medical components such as surgical drills, stents and screens can use a compact electropolishing system to sharpen, deburr, passivate and electropolish their products in-house. Operating under programmable logic control, the system from Metfab Technologies Inc. (Warwick, Rhode Island, USA; www.metfabtech.com) is well suited for certified processes that require complete part and lot traceability. In addition, by eliminating outside vendors and the associated possibilities of quality inconsistency and delayed delivery, it gives manufacturers greater control over production and a stronger sense of security.
Featuring a secure, menu-driven controller that includes more than 10 preprogrammed routines for treatment cycles and can be customised by the user, the electropolishing system performs multiple-step processing of components as large as 8 × 8 × 4 in. (203 × 203 × 102 mm). It is totally enclosed and occupies a footprint of 6 × 3 ft (1.8288 × 0.9144 m). The system can process up to 30 loads an hour, the throughput depending on the nature of the parts or materials. Each unit is built to customer requirements.
Machine control system
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A range of machining centres and lathes are equipped by their manufacturer with an enhanced machine control that runs easy-to-program software. Hurco Europe Ltd. (High Wycombe, UK; www.hurco.co.uk) developed the WinMax control to shorten setup times when its machines are programmed on the shop floor and to optimize the surface finish of components. The control software, which has a new Windows-based interface, is a standard feature on the controls fitted to the company’s machines today. The upgrade introduces sharp colour rendered graphics.
The software includes more than two dozen new and patented features intended to maximize job shop efficiency and productivity. Simple conversational commands and a clear graphical display of both the component and the tool path as it is programmed make machines with WinMax controls suited for small-volume as well as even one-off part manufacture. Swept Surface, for example, helps mould makers by offering a simplified approach to programming and machining complex 3-D parts. The NC/Conversational Merge feature enables G code programs to be called up in the middle of a conversational routine. With Select Surface Finish Quality, the machinist controls component quality and run time by adjusting an on-screen slider bar that automatically changes the program to accord with finish requirements. Another noteworthy new feature is Advanced Verification Graphics with the Solid 3-D Rendering tool.
With the latest software, advances have been made in contouring speeds and data smoothing so that cycle times are shorter and parts can be given a better surface finish. In addition, the software includes an upgrade to the flat-panel screens on machining centres with dual controls; both screens support touch navigation.
