Medical Shops Keep Production High and Costs Low

The medical device manufacturing industry continues to be a double-edged sword for shops. Demand in the sector remains high with a projected compound annual growth rate of 6.2% through 2032. However, the increased demand paired with pressure to keep production costs as low as possible will require manufacturers to streamline processes for maximum volume and output.  

Additionally, the medtech segment inherently requires a tremendous number of tools, parts and consumables. Global demand for single-use instruments, lab utensils, dental and orthopedic implants, bone screws and plates and a legion of other parts produced in large volumes continues to surge.

The specific nature of a high-production part and required job lot sizes will dictate the type of machine tool medical OEMs should consider for efficient, cost-effective production. While there is no medical miracle machine tool suitable for every job, multi-tasking machines, for example, are effective at increasing productivity. However, they are often better suited for complex tasks at certain production output levels. For extremely high-volume production for instance, multiple standalone machines in a cell with robot load/unload automation would prove a better choice.

For those medical jobs that do warrant a multi-tasking machine, Mazak’s INTEGREX i-Series Multi-Tasking machines combine turning, milling, drilling and more, on one machine platform, to significantly reduce setup times and eliminate inaccuracies that occur when moving a part across multiple workstations. This combination of high-power turning machine capability with the performance of a full-function machining center allows for DONE IN ONE® manufacturing for high-level, single-setup production of strict tolerance orthopedic implants.

For high-volume processing of surgical instruments and equipment the VARIAXIS NEO series speeds production. Offering full simultaneous 5-axis machining, VARIAXIS machines perform multiple and complex curved surface machining on workpieces such as knee and hip replacement components and custom implants in single setups for reduced lead times and operating expenses.

High-volume production of small, complex items such as bone screws and pins call for Swiss-style machines, like Mazak’s SYNCREX Swiss-style Turning Machines that are available in 7-, 8- or 9-axis machine configurations. Features such as a High-Damping Composite Casting (HDCC) provide excellent rigidity, less thermal distortion, longer tool life and better finishes, and Mazak’s exclusive in-machine Auto Tool Setter reduces setup time.

Specifically for the SYNCREX Swiss-style machines, Mazak developed its MAZATROL SmoothST control. It features setup and tool data screens, tool setup assist function, a multi-channel system for wait codes and synchronized movement commands along with the ability to verify machine movement before pushing cycle start.

With highly capable machine tool CNCs, such as Mazak’s MAZATROL Smooth Controls, medical manufacturers simplify complex workpiece programming including off-centerline machining and angled drilling, milling and tapping. Mazak Smooth Controls ship with ultra-high-speed machining software and include both MAZATROL Conversational and EIA/ISO G-code programming capabilities for ease of use and flexibility.

Simultaneous 5-axis medical machining involves programming for fine incremental movements. Speed is of the essence in those situations, and Mazak’s user-friendly MAZATROL SmoothAi CNC is the fastest, most progressive control on the market that ensures the shortest possible machining cycle times.

Regardless of the machine technology shops use, efficient, cost-effective medical manufacturing hinges on 24/7 unattended operation. This is why Mazak offers a full range of pre-engineered and custom solutions to meet specific medical production requirements.

As a simple and efficient form of automation, machine tool two-pallet changers boost productivity by allowing operators to load, unload and inspect parts on one pallet, while the machine continues to work uninterrupted on parts fixtured on the other pallet. Taking simple pallet changing a step further, Mazak’s highly scalable PALLETECH system gives medical shops the options for 1-, 2-, and 3-level pallet stocker configurations for high levels of efficiency when processing both high-mix, low-volume production jobs as well as high-volume operations.

When shop floor space is at a premium, automation like Mazak’s MPP (Multi-Pallet Pool) System offers pallet stocker capability but in a more compact footprint for servicing single machine tools. Also for single machine tending automation, Mazak’s Ez LOADER is a stand-alone, plug-and-play cobot that uses a pallet, programmable logic controller and all necessary equipment for machine integration.

Today’s medical manufacturers need more than just machines and automation and look to their technology suppliers for both service and application support. It is for this reason that Mazak provides medical device and instrument manufacturers a comprehensive regional support network of Technology and Technical Centers that offer training, collaboration opportunities with industry partners and new product solution proof of concept testing.

To ensure medical manufacturers match the best machine with the job at hand, Mazak has the most advanced manufacturing technology and support resources in the industry, providing acute market knowledge, an extremely broad machine tool selection and extensive applications expertise. Whether you’re machining trial implants, orthopedic devices or surgical instruments from titanium, Inconel® or stainless steel, we have what you need to optimize your manufacturing operations.

All Mazak machines are backed by Mazak MPower Complete Customer Care, which includes the industry’s best two-year warranty, lifetime parts availability and industry-leading support, training and parts