Medical Sector

Across the wide-ranging realm of medical engineering that spans implantology, microsurgery, diagnostics and dental technology; the following holds true for all areas of application: Premium manufacturing quality is crucial to securing a greater quality of life for patients.

The medical sector is a rapidly-growing manufacturing industry that places special requirements on materials and equipment. The majority of the broad range of products used by this industry, such as surgical instruments and orthopedic implants are made from extremely hard materials. Manufacturers interested in reliably cutting these materials and distinguishing themselves from the competition to gain a reputation as a strong supplier, need to offer a very high level of component quality – all while keeping production times as short as possible.

Industry Challenges

  • Reduce setup times: through complete and multi-axis machining using mill-turn and 5-axis technologies
  • Improve quality: blending strategies minimise additional finishing processes
  • Improve process reliability: through collision-checked toolpaths and reliable simulation technology
  • Demanding materials: through milling strategies that enhance machine and cutter life thanks to HSC and HPC strategies

Speed and performance

Maximum speed, precision and flexibility – high-speed cutting offers users in the medical sector decisive advantages as compared to conventional milling methods. High spindle RPMs and cutting speeds enable short machining times and excellent surface qualities. Both of these are important factors for prosthetics and orthotics.
hyperMILL® offers efficient and easy-to-program HSC strategies for 2.5D, 3D and 5-axis machining in prototype and series manufacturing. High-performance cutting removes the material particularly quickly in a way that is tool-friendly, even when handling difficult-to-machine materials such as titanium and stainless steel alloys.

CAM Strategies for Industry-specific Components

hyperMILL® MAXX MachininghyperMILL® MAXX Machining

HPC roughing

Trochoidal toolpaths are ideally suited for efficiently roughing medical components in a tool-friendly way, even when handling materials that are difficult to machine, such as titanium and stainless steel alloys.

3D Machining3D Machining

Equidistant finishing

3D equidistant finishing makes it possible to machine surface formations with a uniform 3D face infeed. Uninterrupted cutting without any retraction results in very high surface qualities. This finishing strategy is especially well-suited for high-speed cutting.

5-axis Machining5-axis Machining

5-axis swarf cutting

Slightly curved surfaces such as those on bone plates can be swarf-cut with wide path distances. This significantly reduces machining time and guarantees a greatly improved workpiece surface.

hyperMILL® MILL-TURN MachininghyperMILL® MILL-TURN Machining

MILL-TURN Machining

hyperMILL® MILL-TURN Machining offers a comprehensive package for millturn machining for the majority of rotationally symmetrical components used in medical engineering. All common turning operations as well as special strategies such as rollFEED® Turning and 3-axis simultaneous turning are thereby placed in an operating environment with the milling strategies and can be freely combined with these.

Mill turning with hyperMILL® MILL-TURN Machining

Rotationally symmetrical components are frequently used in medical engineering. For this reason, numerous implants and special surgical tools are perfect for millturn machining. To ensure efficient manufacturing of these types of parts, hyperMILL® MILL-TURN Machining offers a comprehensive package that combines all milling, turning, and drilling operations in a single user interface.

Reference

Advantages at a Glance

  • Innovative roughing and finishing strategies: particularly efficient as well as tool- and machine-friendly machining, even when handling difficult-to-machine materials
  • Best-in-class 5-axis strategies: safe machining of complex components and deep cavities using short, stable tools
  • Complete machining: all machining strategies integrated into a single user interface
  • High process reliability: simulation and collision avoidance for safe processes

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