Smart Machining of Medical Implants, Medical Components and More

Equipped with a Heidenhain control system and smart machining modules that provide advanced levels of monitoring that are especially critical to the production of medical implants and equipment, the high speed, fully simultaneous 5-axis machining capabilities of the Mikron MILL S 400 U from GF Machining Solutions LLC (Lincolnshire, IL) provides levels of reliability, traceability and accuracy that are ideal for mold and die machining, as well as post-processing parts and molds produced with additive manufacturing systems. Its control system allows the machine to automatically check and evaluate tools and workpieces, inspect tools for breakage and perform measurements of parts. Additionally, the smart machine modules automatically monitor spindle vibration, calibrate machine geometry and transmit process status messages to an operator’s cell phone.

The MILL S 400 U gets its processing speed from available 28,000 rpm (HSK-E32) and 42,000 rpm (HSK-E40) spindles, along with a fast rapid traverse rate of 2,401 ipm (61 m/min). Using the latest liquid-cooled, direct-drive motor technology, this machine also achieves speeds up to 250 rpm on its rotational axis that swivels in a range of ±110 deg. For 24/7 unattended machining, the MILL S 400 U includes a pallet changer with 18 pallets. Its automation potential is further enhanced through an automatic table and workpiece cleaning system, efficient chip evacuation and the ability to measure parts from outside the work area as the machine continues working uninterrupted. Programmable standby/warm-up schedules can have the machine ready for optimum performance as soon as the operator arrives. Once the machine starts, it accurately controls ambient temperature drifts to deliver high precision over long run times. This thermo-stability allows manufacturers to reliably produce high-quality finished parts with unparalleled throughput.

GF Machining Solutions also offers their Mikron MILL X 600 U milling machine for high precision production of medical parts with complex, concave and convex surfaces. It brings together the perfect blend of ultra-high speed machining, superior surface finishes and exact tolerances, making it ideal for manufacturers who need all three capabilities to compete with offshore competition when it comes to complex part production. Other common applications include the manufacture of aerospace structural parts and closed impellers. This machine packs a 24,000 rpm (36,000 rpm available) high speed spindle and performs full simultaneous 5-axis or 3+2 machining. With its tilt/rotary table, shops gain better access to difficult-to-reach part features and can process parts complete in single clampings, all of which allows them to meet short job turnaround times.

The MILL X 600 U features a polymer concrete base, stiff cast iron sliding carriages and excellent clamping properties to deliver high stability and accuracy. Its X, Y, Z-axis travels measure 31.496 in x 23.622 in x 19.685 in, B-axis travels +30/-110 deg and C-axis 360 deg. The machine rapid traverses at speeds up to 3,937 ipm (100 m/min) and is well suited for serial production of a variety of small- to medium-sized precision parts from stainless alloys and aluminum. The machine can be used with a high precision coordinate measuring machine (CMM) inside a FANUC-automated multi-machine manufacturing cell for full lights-out operation.

For machining medical catheter tips, the high performance Laser P 400 U 5-axis machine and the ultra-fast Microlution ML-5 laser micro machining platform are ideal for shops needing a competitive advantage when machining small, intricate parts. The LASER P 400 U machine includes a patented, dual laser head that incorporates both a fiber nanosecond laser and a femtosecond pulsed laser for texturing, marking and engraving of a surface with a single setup. This also extends the range of materials that can be processed. It is ideal for micro-machining small components, including watches, jewelry, cutting tools, small inserts and other items. With a footprint of only 48.4 in x 87.8 in, the LASER P 400 U easily fits into existing production environments and accommodates workpieces with a maximum diameter and height of 4.7 in. It is automation-ready for unattended night and weekend operations.

The microlution ML-5 ultra-fast laser micro-machining platform is the first industrial-grade femtosecond laser platform capable of machining minute features with micron-level accuracy and repeatability in 24/7 manufacturing environments. Its ultra-fast lasers machine without creating a Heat Affected Zone (HAZ), making them capable of achieving tolerances that would otherwise be impossible. The absence of thermal damage also eliminates post-processing in many applications to further reduce overall part cycle times. The ML-5 has been widely adopted for several critical applications in medical manufacturing, as well as automotive and consumer products that includes drilling automotive fuel injector nozzles, cutting hardened glass used in mobile device displays and machining intricate watch gears.

The versatile, highly efficient FORM 20 die-sinking EDM paired with a System 3R WorkPartner 1+ robot can produce molds for specialized medical devices. The FORM 20 is an ideal system for shops looking to maximize their die-sinking EDM operations while minimizing their environmental footprint. To provide exceptional performance, this machine uses proprietary Intelligent Power Generator (IPG) technology that gives the FORM 20 the lowest energy consumption levels – just 3.7 kW/h at full power – of all EDM machines on the market. This IPG features built-in quality boosting, cost saving intelligence. With every machine pulse, the 70 amp generator continuously optimizes the EDM process and dramatically reduces electrode wear as well as providing extremely uniform surface finishes. This machine reliably generates surface finishes of Ra 0.1 microns and radii down to 0.0007 in.

In addition to its unique power generator, the FORM 20 sports the AC Form HMI (human machine interface). Revolutionary in its simplicity, this CNC provides the most user friendly, easiest to learn and most flexible control developed for a die sinking EDM. Combined with full spark generator technology that represents the culmination of 60 years of EDM experience, AC Form HMI allows operators of all experience levels to achieve unmatched results. As one of the most compact standard die-sinking EDMs, the FORM 20 still provides ample axis travels of 13.78 in x 9.84 in x 9.84 in. Within its space-saving footprint, the machine includes an integrated linear tool changer with up to 200 electrode changing options. It also incorporates a rigid and compact mechanical structure for reliable, stable operation. When paired with the FORM 20, the WorkPartner 1+ provides automatic electrode and parts loading and unloading. Palletization options can accommodate up to 20 pallets to allow for unmanned production and maximize lights-out operations.

GF Machining Solutions LLC, 560 Bond Street, Lincolnshire, IL 60069, 847-913-5300, Fax: 847-913-5340, www.gfms.com/us.