Accuracy and precision are of utmost importance in the medical industry. Therefore, manufacturers use processes that meet tight tolerances and strict regulatory requirements. CNC machining is revolutionizing the healthcare sector. It is an essential technique for producing both small and large medical devices.
The advantages of CNC machining services are unmatched. It is versatile and offers quick and sophisticated production. This article will explain the medical applications of CNC machined parts, materials for medical CNC machining, and factors to consider when selecting medical-grade metals or plastics.
Why is CNC Machining Used in the Medical Industry?
The benefits of using medical CNC machining are numerous. Compared to traditional manufacturing, this process increases productivity and reduces set-up time. The following are some of the reasons why CNC cutting is an essential technique in healthcare.
Material Flexibility
CNC machining can adapt to many materials used in manufacturing medical devices. The use of portable machines and adaptable CAD files makes it possible to produce accurate parts using different grades of materials with high accuracy.
No Minimum Order Requirements
With CNC machining, manufacturers can engage in unlimited part fabrication. This benefit allows for low to medium-scale production of medical parts. Consequently, this process is most suitable when manufacturing custom-made and patient-matched parts such as dental and orthopedic implants.
Complex Shapes and Structures
The medical industry deals with various instruments with intricate shapes and designs. Here, the 5-axis CNC machine, capable of moving across all five axes simultaneously (X, Y, Z, A, and B), proves effective. The extra two axes make it easy to machine very complex designs and structures.
Production Speed
The speed of production is a critical component in the healthcare sector. CNC machining services create a balance between speed and quality. This process is automated and will help get products to market on time. Therefore, manufacturers can further improve speed by optimizing appropriate CNC parameters.
Tight Tolerance Requirements
Medical components often require tight tolerances because lives depend on them. CNC machining is precise and achieves strict tolerances seamlessly. This process reduces the need for further processing.
Medical Applications of CNC Machined Parts
CNC cutting techniques suit the fabrication of equipment used for diagnosis, treatment, and some surgical devices. Let’s explore more specific uses of medical CNC machining.
Medical-instruments
Surgical Instruments
CNC machining services are popular for manufacturing high-grade surgical instruments, including scalpels, scissors, clamps, implant holders, and forceps. These instruments must be manufactured with care as they often come in contact with body fluids and tissues. CNC-machined surgical instruments have a smooth surface and are free of defects.
Orthopedic Implants and Prosthetics
CNC cutting suits the creation of implants that replace cartilage, joints, or bones. These implants must be biocompatible and are usually produced in small quantities. These features make processes like injection molding uneconomical.
Electronic Medical Equipments
Manufacturers also design and produce medical electronic devices using CNC machining. These include ultrasound imaging, MRI scanners, heart rate monitors, pacemakers, X-ray machines, and many more. Many of these pieces of equipment are large, requiring part assembly to make a whole. Therefore, the fabrication of each element must be precise to avoid sudden breakdowns.
Dental Devices and Implants
CNC machining services also suit the fabrication of dental devices and implants. They provide a cosmetic appearance, restore the ability to chew and improve the health of gums. A key concern when employing dental implants is sterility. Dental devices manufactured using CNC cutting are easy to sterilize.
Microdevices
CNC machining also has applications in manufacturing biomedical microsystems, which are usually 1-100 micrometers in size. These microdevices are delicate and come with intricate designs. Examples include stents, microelectrodes, and microsensors.
Instruments for Minimally Invasive Surgery
Minimally invasive surgeons use CNC machined parts to create keyhole incisions. These devices are usually small, as the incisions maybe half an inch long or less. The tools used for this type of operation include neurosurgical endoscopes, laryngoscopic scissors, forceps, and needle holders.
Materials for Medical CNC Machining
Medical CNC machining is a versatile process. It is compatible with both metals and plastic polymers.
Metals and Alloys
The following metals and alloys are durable and are the first choice for CNC machining in the medical industry.
Aluminum
A large percentage of metallic medical equipment consists of aluminum. Aluminum is lightweight, strong, and easily machinable. Furthermore, it has excellent corrosion resistance. A typical property that makes this metal suitable for the medical industry is its chemical resistance. For example, aluminum parts won’t break down after regular sterilization with alkaline cleaning agents.
Titanium
Titanium is one of the go-to materials medical device manufacturers use for implants. This material binds well with human bones and requires a large force to break them apart. In addition, it is highly biocompatible and resists corrosion when in prolonged and direct contact with bodily fluids.
Magnesium
Magnesium-based devices are revolutionizing the medical industry. Like aluminum, magnesium has an excellent strength-to-weight ratio, so it is found in X-ray machines and other large equipment. Furthermore, the use of magnesium implants is becoming common. Magnesium is safe and will not trigger immune reactions.
Copper
Copper is critical in healthcare because of its antimicrobial properties. When specific microbes come in contact with copper surfaces, it attacks their cell membrane and renders them harmless. Hence, copper is a common material used in the manufacturing of electronic medical devices.
Stainless Steel
Different grades of stainless steel have applications in the medical industry. Stainless steel has an attractive appearance and is corrosion-resistant. The property makes it durable during heat sterilization and is easy to clean. Examples of medical stainless steel components include surgical trays, scalpels, and non-permanent implant devices.
Plastics and Polymers
Plastics are another material used in CNC machining medical gadgets. They are lightweight and are more cost-effective. The following are the most common plastic medical manufacturers use
Nylon
Various nylon grades are used in medical CNC machining. They are strong, durable, and stable at high temperatures. The use of nylon as an alternative to medical implants is becoming popular. It is also suitable for manufacturing forceps, sutures, and clamps.
Polycarbonate
The medical uses of CNC machined polycarbonate are endless. Polycarbonate is dimensionally stable, optically clear, and useful for critical applications such as drug delivery systems, some surgical devices, and neonatal care.
ABS (Acrylonitrile Butadiene Styrene)
ABS has three different polymers that complement one another. Though not suitable for implant devices, ABS has other important uses because of its excellent mechanical properties. It is used to manufacture drug delivery systems, pharmaceuticals, and casings for medical components.
PTFE (Polytetrafluoroethylene)
PTFE is an excellent medical-grade plastic due to its inertness and high corrosion resistance. It is stable when in contact with solvents and harsh chemicals. Its applications include its use in creating prosthetics and catheters.
PEEK (Polyether Ether Ketone)
PEEK is another plastic suitable for medical applications. It is non-toxic and can withstand extreme temperatures. Applications include use in ophthalmic devices, surgical instruments, dental applications, and implants.
PE (Polyethylene)
PE is a high-grade engineering plastic. Its most common application is the manufacturing of implants. It has similar mechanical properties to human bone and permits more movement.
Acrylic
The use of acrylic for medical devices is nothing new. It has glass-like properties such as clarity, transparency, and UV resistance. However, it weighs less, though it is highly strong. Acrylic is suitable for optical lenses, disposable syringes, and incubators.
Factors to Consider When Choosing Materials for Medical CNC Machining
There is no standard way of selecting materials for medical CNC machining. A myriad of factors come into play. The following are some of the factors that one ought to consider.
Biocompatibility
The most essential factor to consider when selecting a material for fabricating medical devices is its biocompatibility. The material for manufacturing medical parts, especially those in prolonged contact with body fluids and tissues, must be biocompatible. It must not be toxic, react, or trigger immune reactions. Titanium, stainless steel, and some plastic types are the most suitable.
Electrical Requirements
Not all medical-grade materials conduct electricity. The material used to manufacture electronic medical devices like pacemakers must be a good conductor of electricity to a large extent. Most plastics and polymers are good insulators and may not meet this criteria, though they benefit other applications in the medical industry.
Sterilization Compatibility
Many medical devices are required to be sterilized during production and use to avoid contamination. Not all materials can withstand the rigors that come with sterilization. The metal or plastic must be stable when heat or UV is applied.
Wear Resistance
Wear and tear resistance is another essential factor when selecting materials for manufacturing medical devices. For parts that will be used continuously for a long time, employing materials such as copper alloys, acetal, and nylon is most appropriate.
Mechanical Properties
The mechanical properties of a material must also be considered before using it to construct medical devices. Check for hardness, tensile strength, flexibility, stiffness, and elasticity.
Aesthetics and Physical Appearance
In addition to functionality, aesthetics also plays a role in the medical industry. Aesthetic designs promote the treatment experience and users’ confidence. Materials manufacturers use to produce breast prosthetics and implants must be sleek and have a fine surface finish.
Cost and Availability
One must also factor in the cost of production and readily available materials. Aluminum, magnesium, and polyethylene are abundant and the cheapest medical-grade materials.
Regulatory Compliance
Before selecting a material for your CNC machined parts, consider the healthcare rules and guidelines. Not all materials are certified for use in some applications. For those devices that must come in contact with bones or tissues, the materials must have been tested and approved.
The Future of CNC Machining in the Medical Sector
The medical CNC machining process is dynamic and will continue to evolve. Researchers need to improve on some aspects. The following are some future trends and expectations of CNC cutting in the medical sector.
Integration with Additive Manufacturing
Combining CNC machining services and additive manufacturing is already gaining popularity. However, it is constantly under review to make the integration seamless and ensure the fabrication of parts that adhere to all design specifications. This hybrid process exploits the advantages of CNC machining and additive manufacturing, like 3D printing. It offers more design flexibility and reduces production time.
Enhanced Automation and Digitalization
In the future, medical CNC machining services will be more automated and digitalized. It will involve the use of robotics and less human interaction. The robots will be preprogrammed to carry out some activities, such as moving in the raw materials and deburring the final parts.
Integration with Industry 4.0
Integration with the fourth industrial revolution will transform medical CNC machining over time. It involves using advanced technologies to collect and analyze data in real-time, which can give businesses a competitive edge in the market.
Improved Software with a Wider Range of Materials
CNC machining is not compatible with all engineering materials. However, with new and improved software, medical CNC machining will work perfectly with ceramics, glass, and heat-sensitive materials.
Conclusion
Medical CNC machining is at the center of modern manufacturing techniques. This process is time-efficient, versatile, and reliable. However, it is expensive and may result in material waste. The future of CNC machining is bright. Technological advancements such as the use of AI and robotics will drive medical CNC machining for years to come.
FAQs
What Are the Four Stages of Medical CNC Machining?
The four stages of medical CNC machining include creating the CAD model, converting the CAD model to a CNC file, configuring the CNC machine, and executing the machine operation.
How Long Does Medical CNC Machining Take?
Based on the complexity of the design, the time interval between creating the 3D model of the final design and getting the final product can be between a few hours and some days.
What Are the Types of CNC Machining Processes Used in the Medical Industry?
The main types of medical CNC machining operations are milling, grinding, laser cutting, and turning.
