https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/06/01171357/Fig-2-500x260.jpg
    Manufacturing

    Cutting tools for miniature medical parts

    • By Iscar
    • June 1, 2020
    • 4 minute read

    The development of innovative parts in the miniature dental and medical industry presents a formidable and equally dynamic challenge.

    The fast-growing field is driven by orthopaedic surgeons and dental professionals together with screw and implant companies transforming inventions into parts. Each new component demands advanced tools and geometries to create new and complex shapes.

    The materials used are often titanium alloys and hard materials where a special ratio of the depth of cut to chip thickness is required. These materials cause built-up edges (BUE), which tend to wear down edge sharpness.

    ISCAR, has developed solutions with new geometries, tools and grades. Creating custom tool assemblies according to ISO: 13399, ISCAR developed tools for miniature medical parts, dental screws and components for hip joint replacement implants – femoral head, acetabular shell, femoral stem and bone plates.

    Dental Screws

    ISCAR developed two options for rough OD turning. The SWISSCUT compact tool is designed for Swiss-type CNC lathes and reduces setup and indexing times. The inserts are equipped with chip deflectors for machining small parts. The second option features SWISSTURN toolholders and JETCUT high-pressure coolant tools.

    CHATTERFREE endmills are applied to slot milling to maximize stock removal rates, eliminate vibration and reduce cycle time.  PENTACUT parting and grooving inserts perform the cut-off operations whereas the SWISSCUT tools are used in the face and OD turning (screw head-turning) operation and the drilling operation is performed by SOLIDDRILL solid carbide drills with 3xD and 5xD drilling depths and right-hand cut. Solid carbide SOLIDMILL endmills with 2 flute, 30° helix medium length, perform the key head milling operation.

    Hip Joint Replacement

    Complex operations are involved in machining components for hip joint replacement, which demands high accuracy, pristine surface quality and absolute reliability. Femoral head machining involves rough turning or grooving, semi-finish profile turning, rough drilling, semi-finish milling, semi-finish internal turning, internal grooving, cut-off and semi-finish turning.

    ISOTURN tools may be used for rough turning. The trigon turning inserts for axial and face turning feature six 80° corner edges. For profile machining, ISCAR provides intricate and precise V-LOCK V-shaped special profile grooving inserts for the range of 10 to 36mm. The CHATTERFREE 4-flute endmills for semi-finish machining feature 38° helix and variable pitch for chatter dampening with 3xD neck relief.

    Acetabular Shell

    Machining of the acetabular shell consists of rough internal turning, finish profile milling, shouldering, upper and bottom chamfering, drilling, thread milling, external rough turning and external grooving. Here, the HELI-GRIP double-ended inserts are used for rough internal turning and internal finish milling is performed by the SOLIDMILL 3-flute, 30° helix short solid carbide ball nose endmills. Thread milling is performed by SOLIDMILL solid carbide internal threading endmills, which integrate coolant holes for ISO thread profiles.

    Femoral Stem

    Machining the femoral stem involves slotting, spot milling, drilling, chamfer milling, turning, face and profile milling operations.

    MULTI-MASTER endmills for slotting feature no setup time and a carbide thread connection for a quick change, and conical and face contact for high precision and rigidity. Spot milling is performed using SOLIDMILL endmills with 4 flutes, 38° helix and variable pitch for chatter dampening with 3xD relieved necks.

    Bone Plate

    Bone plate machining involves rough and finish milling, shouldering, drilling, and mill threading. For rough milling, the FINISHRED endmill geometries perform roughing and finishing operations at the same time. The MULTI-MASTER interchangeable solid carbide tapered heads are then applied to the finish milling operation, whereby the curved surfaces can be machined by tilting the tool and applying a large corner radius at small cutting depths.  For the final milling stage, the MULTI-MASTER  4 flute ball nose endmills are once again introduced. It is no small challenge to manufacture miniature medical parts but ISCAR has succeeded in developing highly effective cutting tools for this field that adhere to the stringent standards of the medical industry.

    https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/06/01171357/Fig-2-500x260.jpg

    Cutting tools for miniature medical parts

    The development of innovative parts in the miniature dental and medical industry presents a formidable and equally dynamic challenge.

    The fast-growing field is driven by orthopaedic surgeons and dental professionals together with screw and implant companies transforming inventions into parts. Each new component demands advanced tools and geometries to create new and complex shapes.

    The materials used are often titanium alloys and hard materials where a special ratio of the depth of cut to chip thickness is required. These materials cause built-up edges (BUE), which tend to wear down edge sharpness.

    ISCAR, has developed solutions with new geometries, tools and grades. Creating custom tool assemblies according to ISO: 13399, ISCAR developed tools for miniature medical parts, dental screws and components for hip joint replacement implants – femoral head, acetabular shell, femoral stem and bone plates.

    Dental Screws

    ISCAR developed two options for rough OD turning. The SWISSCUT compact tool is designed for Swiss-type CNC lathes and reduces setup and indexing times. The inserts are equipped with chip deflectors for machining small parts. The second option features SWISSTURN toolholders and JETCUT high-pressure coolant tools.

    CHATTERFREE endmills are applied to slot milling to maximize stock removal rates, eliminate vibration and reduce cycle time.  PENTACUT parting and grooving inserts perform the cut-off operations whereas the SWISSCUT tools are used in the face and OD turning (screw head-turning) operation and the drilling operation is performed by SOLIDDRILL solid carbide drills with 3xD and 5xD drilling depths and right-hand cut. Solid carbide SOLIDMILL endmills with 2 flute, 30° helix medium length, perform the key head milling operation.

    Hip Joint Replacement

    Complex operations are involved in machining components for hip joint replacement, which demands high accuracy, pristine surface quality and absolute reliability. Femoral head machining involves rough turning or grooving, semi-finish profile turning, rough drilling, semi-finish milling, semi-finish internal turning, internal grooving, cut-off and semi-finish turning.

    ISOTURN tools may be used for rough turning. The trigon turning inserts for axial and face turning feature six 80° corner edges. For profile machining, ISCAR provides intricate and precise V-LOCK V-shaped special profile grooving inserts for the range of 10 to 36mm. The CHATTERFREE 4-flute endmills for semi-finish machining feature 38° helix and variable pitch for chatter dampening with 3xD neck relief.

    Acetabular Shell

    Machining of the acetabular shell consists of rough internal turning, finish profile milling, shouldering, upper and bottom chamfering, drilling, thread milling, external rough turning and external grooving. Here, the HELI-GRIP double-ended inserts are used for rough internal turning and internal finish milling is performed by the SOLIDMILL 3-flute, 30° helix short solid carbide ball nose endmills. Thread milling is performed by SOLIDMILL solid carbide internal threading endmills, which integrate coolant holes for ISO thread profiles.

    Femoral Stem

    Machining the femoral stem involves slotting, spot milling, drilling, chamfer milling, turning, face and profile milling operations.

    MULTI-MASTER endmills for slotting feature no setup time and a carbide thread connection for a quick change, and conical and face contact for high precision and rigidity. Spot milling is performed using SOLIDMILL endmills with 4 flutes, 38° helix and variable pitch for chatter dampening with 3xD relieved necks.

    Bone Plate

    Bone plate machining involves rough and finish milling, shouldering, drilling, and mill threading. For rough milling, the FINISHRED endmill geometries perform roughing and finishing operations at the same time. The MULTI-MASTER interchangeable solid carbide tapered heads are then applied to the finish milling operation, whereby the curved surfaces can be machined by tilting the tool and applying a large corner radius at small cutting depths.  For the final milling stage, the MULTI-MASTER  4 flute ball nose endmills are once again introduced. It is no small challenge to manufacture miniature medical parts but ISCAR has succeeded in developing highly effective cutting tools for this field that adhere to the stringent standards of the medical industry.