Pushing the Boundaries of Precision: Advanced Approaches for Tomorrow's Medical Manufacturing

As a significant consumer of cutting tools, the medical sector presents unique challenges and demands specific features from tool manufacturers. This article delves into the complexities of machining various medical components, particularly emphasizing the pivotal role of tools in orthopedic component machining and identifying emerging trends in cutting tool technology.

Within this realm, cutting tools are specialized for machining small-sized and miniature parts within confined spaces, categorized under main application groups ISO S and ISO M. These tools are meticulously designed to meet stringent requirements for high accuracy and surface finish. The utilization of small tool diameters in rotating tools results in substantially increased rotary velocities, necessitating balance and dynamic strength margins for optimal performance at high speeds.

The influence of cutting tool design engineers on the development of new tools is of paramount importance, with recent products from ISCAR exemplifying advancements in this area. Notably, the PICCOCUT line of miniature tools is highlighted for its innovative coolant-through-tool mechanism, which delivers pinpointed emulsion directly at the cutting edge, thereby enhancing efficiency. Additionally, the article explores double-sided holders equipped with internal coolant channels and a user-friendly clamping mechanism, ensuring high stiffness clamping for enhanced cutting performance.

For machining orthopedic medical components, ISCAR introduces turning tools with ISO standard inserts tailored for Swiss-type and CNC lathes. These tools incorporate the SAFE-T-LOCK clamping mechanism for precise and extremely rigid insert mounting. Furthermore, the availability of a high-pressure cooling option enhances turning operations under challenging conditions, ultimately improving productivity and extending tool life.

Recognizing the cost-saving potential of narrow widths of cut, ISCAR introduces a new range of compact tools with SELF-GRIP inserts, facilitating slim cuts and minimizing material waste. These tools, designed for Swiss-type machines, are well-suited for machining narrow external grooves.

Addressing challenges in miniaturization, ISCAR’s recent reduction in the lower limit of the diameter range for SUMOCHAM drills with interchangeable carbide heads to 4.5 mm represents a significant advancement in cost-efficient assembled drills for the medical industry.

The article further discusses theoretical aspects of ball-nose milling cutters for fine milling complex-shaped parts, emphasizing the challenges associated with cycle time increase due to diminishing step size. Introducing barrel-shaped mills or “segment mills” as an effective solution, especially in five-axis profile machining of formed orthopedic components, ISCAR’s addition of high precision “cutting barrels” to its product range targets semi-finishing and finishing of common materials in the medical industry such as titanium, superalloys, and austenitic stainless steel. Barrel-shaped mills offer a smoother surface, reduce the number of cuts, and decrease process time.

Small-size rotary tools for cutting operations, including milling, drilling, engraving, and deburring, demand substantial rotating velocity, particularly in high-speed machining (HSM) strategies. ISCAR addresses this demand with its new high-pressure coolant-driven MICRO 90 spindles, enabling rotating velocities in the range of 35,000-53,000 rpm while the main machine spindle remains idle.

In conclusion, the rapidly expanding medical industry, with its focus on new engineering materials and technologies, relies on innovative machining solutions provided by tool manufacturers. The article underscores the evolving nature of these trends, challenging the medical industry to seek solutions from tool manufacturers who remain attuned to changing industry demands to offer optimal solutions for machining complex medical components.