Achieve a Mirror Finish on Knee Implants in Under 60 Minutes
Achieve a Mirror Finish on Knee Implants in Under 60 Minutes
In the past, the mass production of knee implants typically relied on mechanical processes such as robotised belt polishing or abrasive polishing. These methods involve creating friction on the surface of the implants using an abrasive. However, these traditional approaches often encountered several issues, including time-consuming procedures and the possibility of components requiring rework or even being scrapped.
In this case study, we explore a more cost-effective solution that enhances the surface finish of knee implants, leading to improved functionality and an extended lifespan.
Project Background
Client is a multinational medical company primarily engaged in medical device and implants development and manufacturing, with a prominent presence in the orthopedic implant manufacturing sector. Focused on driving innovation in orthopedics, they had specific objectives:
- Enhance the production efficiency and quality of casting cobalt-chrome (CoCr) femoral components, which constituted 80% of their manufacturing output.
- Polish knee implants that underwent initial manual polishing using belts, ceramic, plastic, and nutshell abrasive techniques, aiming for a final manual buffing.
- Attain a mirror-like surface finish, significantly reducing roughness to achieve a targeted Ra (roughness average) value of 0.05 micrometers.
Solution
A batch of cobalt-chrome knee implants samples, in different sizes, were prepared for trial purposes. The objective of these trials was to identify the optimal process parameters and steps required to achieve the desired final finish while minimising processing time and reducing costs.
For this purpose, the DLyte PRO500 Technology was used, as it is a compact and efficient machinery tailored for mass production, capable of handling up to 24 knee implants per cycle.
The processing time for each batch was set at 60 minutes, accommodating 24 pieces at once. Initially, the average roughness measured 0.2 microns. However, after subjecting the components to two stages of abrasive finishing using ceramic and plastic media, the final roughness was impressively reduced to below 0.05 microns.
Process Benefits
- Offers finishing solution for a wide range of materials
- Component’s geometry and tolerance is preserved
- Homogeneous results every time
- Can reduce the roughness over 80% without side effects
- Longer lifespan for components
- Improved resistance to part wear and fracture resistance.
- No contamination and no traces of hydrogen on the surface.
- Biocompatibility and non-cytotoxicity proved
- This finishing process implies a production cost reduction of over 60%.
- Quick and easy change of media for different process.
Results
- The finishing process resulted in mirror finished knee implants; while the surface roughness was reduced under 0,05 micrometers.
- Finishing cost per piece was reduced to €2 for 5 years with 40,000 pieces/year (this includes equipment and customised holder investment)
- The processing time was improved to 60 minutes with a capacity of 24 pieces per batch.
- Parts were finished to client’s specifications, without altering the geometry.
- DLyte PRO500 offered a high-quality repeatable process.
Before / After
Interested in Finding out More?
If you would like to learn more about the process steps and technology used, you can request the Knee Implants Case Study. You can also email our technical team for technical support with your medical and healthcare components.
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