Cutting-Edge CNC Technology for Breakthroughs in Medical Device Production

Aerospace and 5-axis Program Manager

A portion of this article first appeared in the January/February 2025 issue of Today’s Medical Developments.

For 2025, there are tremendous opportunities for using the latest CNCs and related technology to service the changing medical device and equipment industry. With more customized joint replacements that fit the patient’s body more precisely, a retooling of medical device production is now becoming necessary.

Because the industry is moving away from using generic joint replacements, where a patient’s bone structure was altered to suit the device, and moving towards using custom replacement joints via scanning technology, medical device producers must also change their manufacturing operations. The process must now entail a mix of additive manufacturing, CNC machining and accurate CNC part programming to adjust to this bespoke joint replacement.

The Importance of CNCs in Additive Manufacturing

Additive manufacturing has been a game changer for the medical device production industry. The ability to effectively produce highly engineered metal components through processes like laser powder bed fusion (LPBF) on metal additive machines has been fundamental to fuel the medical device replacement production and procedure advances.

However, more than just 3D printing is necessary to make the production process successful. CNC machining is still important to achieving the tight tolerances, necessary polished surface finish, and accuracy needed for the customized metal joint. The key to this hybrid approach is using the new CNC technology and solutions available.

Machine tools that have powerful controls with advanced functions for optimal 5-axis tool paths can significantly help medical device producers get the most out of their 5-axis machining. While it’s possible to do the required 5-axis machining with legacy controls or functions, the workflow is significantly simplified with modern CNC functionality.

CAM Programming and the CNC

An integrated software solution for CAM programming and machine controls must be in place before any advanced CNC machining can occur. The CAM system determines the required tool path and approximates it with a sequence of points. The post processor translates those points to a specific machine and CNC application. Tools that help set up posts for optimal functionality can simplify this process. For instance, FANUC’s advanced functions like Workpiece Setting Error Compensation (G54.4) and Tool Center Point (G43.4/G43.5) can eliminate complex math from post processors and create part programs that are machine independent. Thereby programming parts, not machines, the same part can be run on multiple machines even those with mechanical differences.

Additionally, FANUC’s CNC GUIDE 2 and Surface Estimation Tool replicates real-world surface finish results in digital simulations to accurately check not only the part shape, but also machining quality level. Prior to any real-world cutting, the software precisely estimates a part’s machined surface by using the position data of each axis then simulating the cutting to detect machining issues. Knowing this before cutting helps avoid wasting valuable time and materials that otherwise might be produced with marks or other surface defects.

Key Takeaways

The outlook for medical device production in 2025 is exciting with technological advancements coming together creating phenomenal industry changes. However, the CNC is still as important to medical device production as it was years ago. Keeping up with the latest CNC technology and CAM solutions promises to be even more important going forward. Don’t let that become your production pitfall to evolving with the industry.

Cutting-Edge CNC Technology for Breakthroughs in Medical Device Production

Aerospace and 5-axis Program Manager

A portion of this article first appeared in the January/February 2025 issue of Today’s Medical Developments.

For 2025, there are tremendous opportunities for using the latest CNCs and related technology to service the changing medical device and equipment industry. With more customized joint replacements that fit the patient’s body more precisely, a retooling of medical device production is now becoming necessary.

Because the industry is moving away from using generic joint replacements, where a patient’s bone structure was altered to suit the device, and moving towards using custom replacement joints via scanning technology, medical device producers must also change their manufacturing operations. The process must now entail a mix of additive manufacturing, CNC machining and accurate CNC part programming to adjust to this bespoke joint replacement.

The Importance of CNCs in Additive Manufacturing

Additive manufacturing has been a game changer for the medical device production industry. The ability to effectively produce highly engineered metal components through processes like laser powder bed fusion (LPBF) on metal additive machines has been fundamental to fuel the medical device replacement production and procedure advances.

However, more than just 3D printing is necessary to make the production process successful. CNC machining is still important to achieving the tight tolerances, necessary polished surface finish, and accuracy needed for the customized metal joint. The key to this hybrid approach is using the new CNC technology and solutions available.

Machine tools that have powerful controls with advanced functions for optimal 5-axis tool paths can significantly help medical device producers get the most out of their 5-axis machining. While it’s possible to do the required 5-axis machining with legacy controls or functions, the workflow is significantly simplified with modern CNC functionality.

CAM Programming and the CNC

An integrated software solution for CAM programming and machine controls must be in place before any advanced CNC machining can occur. The CAM system determines the required tool path and approximates it with a sequence of points. The post processor translates those points to a specific machine and CNC application. Tools that help set up posts for optimal functionality can simplify this process. For instance, FANUC’s advanced functions like Workpiece Setting Error Compensation (G54.4) and Tool Center Point (G43.4/G43.5) can eliminate complex math from post processors and create part programs that are machine independent. Thereby programming parts, not machines, the same part can be run on multiple machines even those with mechanical differences.

Additionally, FANUC’s CNC GUIDE 2 and Surface Estimation Tool replicates real-world surface finish results in digital simulations to accurately check not only the part shape, but also machining quality level. Prior to any real-world cutting, the software precisely estimates a part’s machined surface by using the position data of each axis then simulating the cutting to detect machining issues. Knowing this before cutting helps avoid wasting valuable time and materials that otherwise might be produced with marks or other surface defects.

Key Takeaways

The outlook for medical device production in 2025 is exciting with technological advancements coming together creating phenomenal industry changes. However, the CNC is still as important to medical device production as it was years ago. Keeping up with the latest CNC technology and CAM solutions promises to be even more important going forward. Don’t let that become your production pitfall to evolving with the industry.

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