Product processing characteristics
In the field of artificial joint manufacturing, ultra-high molecular weight polyethylene tibial pads, as the core components of knee replacement surgery, need to meet the precision size requirements of 63×41×26mm. This material has become the preferred material for artificial joints due to its 9 comprehensive properties such as wear resistance, self-lubrication, corrosion resistance, and biocompatibility. However, the high toughness and low thermal conductivity of the material itself bring special challenges to precision milling.
Industry manufacturing pain points
Traditional machining solutions face three dilemmas:
The amount of machining burrs exceeds the standard, and manual deburring processes need to be added, and the processing time for a single piece exceeds 20 minutes
The surface roughness fluctuates greatly (Ra 0.8-1.2μm), affecting the smoothness of implant movement
Cutting fluid must be used, and the subsequent cleaning process consumes a lot of energy and has environmental risks
MID solution technology breakthrough
For the special requirements of medical implant processing, MID Solutions build a triple technical defense line:
Ultrasonic green engraving and milling system: 20kHz high-frequency vibration achieves "micron-level" intermittent cutting, suppressing burr generation from the root
Supercritical CO₂ internal cooling technology: -56℃ low-temperature airflow accurately cools the cutting area, replacing traditional cutting fluid
Customized diamond tool: with ultrasonic heat shrink ring spray tool handle, achieve ±0.003mm processing stability
Implementation results of the plan
Actual production data shows: the burr residue is reduced by 92%, and the manual deburring process is completely eliminated; the surface roughness is stably controlled at Ra<0.4μm, meeting the requirements of joint surface polishing level; at the same time, the cost of cutting fluid procurement and post-cleaning is eliminated, and the comprehensive processing cost of a single piece is reduced by 37%. According to biomechanical testing, the wear rate of the machined parts is 60% lower than that of traditional processes.
As an innovator in the field of precision machining, MID has focused on high-end manufacturing fields such as medical and aerospace for 15 years. The company has built a full-chain service capability from tool design, process development to intelligent equipment, and is promoting the continuous upgrading of medical manufacturing towards green precision.
