Orthopedics

Manufacturing the femoral component for knee implants presents significant challenges. Achieving precise curvature and smoothness on the condyle surfaces requires adherence to strict tolerances. GF Machining Solutions, in collaboration with Seco and OpenMind, devised an innovative milling approach by using the 5-axis Mikron MILL S 600 U, specialized cutting tools and a custom CAM program. This unique collaboration allowed:

• Reducing the overall machining time
• Eliminating the need for grinding
  
• Enhancing surface roughness

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Additive manufacturing opens the door to new design capabilities and the use of innovative structures. Trabecular titanium structures duplicating the behavior of natural bone have become the technology of choice. Together with 3D Systems, GF Machining Solutions has developed two lines of machines offering a true turnkey approach in Direct Metal Printing : the Factory line and the Flex line. The DMP Factory 500 offers:

• An Automation-ready solution capable of 24/7 operation
• A build volume of 500 x 500 x 500 mm for large batches of products
• Industry-leading end product quality (lowest oxygen levels)
• A full portfolio of materials including three grades of titanium and NiCr
  
• World-class device design software through 3DXpert®

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Hip, shoulder and knee implants are complex devices that have many critical features. Manufacturers face many challenges in order to balance the product's functional requirements, cost and risk. By using our Laser texturing solutions, customers can:

• Have multiple different textures on the same device in a single set-up, no masking required
• Create special surfaces, potentially with anti-bacterial properties
• Integrate UDI and anti-counterfeiting measures in the same setup as texturing

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Bone plates are special implants that are used to immobilize bone segments after orthopaedic surgery, and can be specialized for different types of usage, such as protection or bridging. Creating such implants from biocompatible metals requires using dedicated manufacturing solutions, among which milling has a place of choice.

GF Machining Solutions has studied and developed the use of supercritical CO₂ as a coolant for milling. In our latest webinar, we explore the trends of the medical device manufacturing and explain how supercritical CO₂ can be considered as a potential game changer for efficient milling.

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Designed to replace damaged parts of the shoulder, special prosthesis of the shoulder - also called shoulder implants - can be manufactured with Additive Manufacturing (AM).  

In our webinar we examined the market trends and the challenges in the use of AM for implants. Discover the key success factors that can enable efficient operations through the full AM value chain.

Watch the webinar