In the medical field, precision isn’t optional—it’s life-critical. This case study highlights how our machining expertise helped a leading medical device manufacturer overcome a challenging production issue involving a tight-tolerance orthopedic implant.
If you’re in the medical, aerospace, or energy sectors, and looking for real-world proof of high-stakes machining solutions, this example will resonate.
The Client’s Challenge: A Critical Orthopedic Implant with Sub-10 Micron Tolerances
A medical equipment company approached us with a recurring problem: their existing supplier was unable to consistently produce a hip implant component that required:
- ±5 micron tolerances
- Mirror-finish surface (Ra < 0.2 μm)
- Biocompatible titanium alloy (Ti-6Al-4V)
- Complex 3D geometry with thin walls
These inconsistencies were causing regulatory delays, production rework, and potential failure risks in clinical trials.
The client needed a shop that could deliver flawless parts—fast.
Our Precision Solution: Smart Setup + Advanced Tooling + In-Process Inspection
We immediately began with a DFM (Design for Manufacturability) review, working closely with the client’s engineering team to understand the intent behind the design.
Here’s how we solved it:
🔧 Machine Selection:
We used a 5-axis CNC machining center with thermal compensation, ideal for high-precision titanium work.
🛠 Tooling Optimization:
Custom-ground carbide end mills with specialized coatings were used to reduce chatter and extend tool life when cutting Ti-6Al-4V.
📏 In-Process Probing & CMM Validation:
We deployed on-machine probing for real-time measurement and CMM verification after each batch, ensuring consistent ±5 micron tolerance.
🧼 Surface Finishing:
A two-step micro-polishing process achieved a Ra value of 0.16 μm, exceeding industry standards for implant-grade surfaces.
The Results: Precision Achieved, Time Saved, Trust Earned
✅ Zero rejections over a 1,000-part batch
✅ 30% reduction in machining time through cycle optimization
✅ Pass rate improved from 70% to 100%
✅ Helped client pass FDA audits and accelerate product launch
Our consistent quality and collaborative approach turned a costly issue into a competitive advantage for the client.
Conclusion: Real Results for High-Stakes Industries
This project is just one example of how we tackle complex challenges in precision medical machining. Whether you’re in the medical, aerospace, or energy sector, we bring deep technical knowledge, top-tier equipment, and a commitment to results.
Have a complex machining challenge in your industry?
Let’s solve it together—contact us today to discuss your project
Case Study: Solving a Complex Machining Challenge for the Medical Industry
In the medical field, precision isn’t optional—it’s life-critical. This case study highlights how our machining expertise helped a leading medical device manufacturer overcome a challenging production issue involving a tight-tolerance orthopedic implant.
If you’re in the medical, aerospace, or energy sectors, and looking for real-world proof of high-stakes machining solutions, this example will resonate.
The Client’s Challenge: A Critical Orthopedic Implant with Sub-10 Micron Tolerances
A medical equipment company approached us with a recurring problem: their existing supplier was unable to consistently produce a hip implant component that required:
- ±5 micron tolerances
- Mirror-finish surface (Ra < 0.2 μm)
- Biocompatible titanium alloy (Ti-6Al-4V)
- Complex 3D geometry with thin walls
These inconsistencies were causing regulatory delays, production rework, and potential failure risks in clinical trials.
The client needed a shop that could deliver flawless parts—fast.
Our Precision Solution: Smart Setup + Advanced Tooling + In-Process Inspection
We immediately began with a DFM (Design for Manufacturability) review, working closely with the client’s engineering team to understand the intent behind the design.
Here’s how we solved it:
🔧 Machine Selection:
We used a 5-axis CNC machining center with thermal compensation, ideal for high-precision titanium work.
🛠 Tooling Optimization:
Custom-ground carbide end mills with specialized coatings were used to reduce chatter and extend tool life when cutting Ti-6Al-4V.
📏 In-Process Probing & CMM Validation:
We deployed on-machine probing for real-time measurement and CMM verification after each batch, ensuring consistent ±5 micron tolerance.
🧼 Surface Finishing:
A two-step micro-polishing process achieved a Ra value of 0.16 μm, exceeding industry standards for implant-grade surfaces.
The Results: Precision Achieved, Time Saved, Trust Earned
✅ Zero rejections over a 1,000-part batch
✅ 30% reduction in machining time through cycle optimization
✅ Pass rate improved from 70% to 100%
✅ Helped client pass FDA audits and accelerate product launch
Our consistent quality and collaborative approach turned a costly issue into a competitive advantage for the client.
Conclusion: Real Results for High-Stakes Industries
This project is just one example of how we tackle complex challenges in precision medical machining. Whether you’re in the medical, aerospace, or energy sector, we bring deep technical knowledge, top-tier equipment, and a commitment to results.
Have a complex machining challenge in your industry?
Let’s solve it together—contact us today to discuss your project