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Though medical device manufacturing is maintaining its upward trajectory with a projected compound annual growth rate of 5.5% from 2021 to 2028, post-pandemic headwinds continue to challenge the sector. The high and rising costs of healthcare remain a top concern as orthopedic device and surgical instrument manufacturers seek ways to streamline production while keeping pace with industry demands.
Mazak has a long, close relationship with the medical manufacturing industry, particularly in the realm of orthopedic devices and instruments. It works closely with medical customers worldwide to monitor trends, identify challenges and develop machine tools and technologies for medical component processing from prototyping to high-volume production applications.
The physical properties and characteristics that make stainless steel, Inconel® and titanium essential for orthopedic components and instruments are the same features that make them difficult to process. Machining the necessary tolerances and surface finishes for these medical components from materials that are hard, tough and subject to work hardening is a difficult proposition. The challenge is made all the more demanding when repeatability and cost-effective production are required.
Mazak has developed several machines uniquely suited to medical device and instrument manufacturing. The QUICK TURN 250MSY Turning Center, INTEGREX i-200H ST, VARIAXIS i-600 and SYNCREX 38/9 are capable, high-speed machining technologies that provide the excellent surface finishes required for medical implants and devices while also accelerating time to market.
The QUICK TURN 250MSY offers advanced Multi-Tasking capability and performance for shops of any size. In addition to milling and Y-axis processing capabilities, the QUICK TURN 250MSY has a second turning spindle for DONE IN ONEÒ single-setup operations.
The INTEGREX i-Series of Multi-Tasking machines also allows for DONE IN ONEÒ manufacturing that delivers speed, accuracy and ease of use to manufacturers of complex medical components. The series includes the INTEGREX i-200H ST Multi-Tasking Center that combines the capabilities of a high-powered turning center with the performance of a full-function machining center for the highest level of single-setup processing versatility.
The VARIAXIS i-600 allows device makers to process parts from raw material input through final machining on one machine. A fully simultaneous 5-axis machining center, the VARIAXIS i-600 performs multiple and complex curve surface machining on small- and medium-sized workpieces such as knee and hip replacement parts, custom clamps and custom implants in single setups to reduce production lead times and operating expenses.
The latest addition to the company’s lineup of fast, precision machining technology is the SYNCREX Series of Swiss-style turning machines that provide manufacturers with a feature-rich platform to meet the growing demand for low mix/high production and high mix/low production. The machines are especially adept at machining small, complex parts such as bone screws and pins.
Within the SYNCREX series, the SYNCREX 38/9X has a 1.5-inch bar capacity and comes with fully programmable B-axis contouring capability for head 1 and head 2. B-axis capability allows the tool to be manipulated at any angle, enabling manufacturers to machine complex medical components by contour milling the face of a part in a single setup.
Advanced MAZATROL Smooth CNC machine controls on all Mazak machine technology make complex 5-axis and single-setup manufacturing for detailed parts and exceptional surface finishes nimble and cost-efficient.
In addition to machine technology for the shop floor, Mazak provides medical device and instrument manufacturers with a comprehensive regional support network of Technology and Technical Centers that provide training, collaboration opportunities with industry partners and new product solution proof of concept testing. The company’s Northeast Technology Center in Windsor Locks, Connecticut, and its Dallas Technical Center, located in Southlake, Texas, focus on medical manufacturing.
All Mazak machines are backed by MPower Complete Customer Care, which includes the industry’s best two-year warranty, lifetime parts availability and industry-leading support, training and parts.
