Oak View Tools’ Integrex 200-IV S not only hard-machines all the shop’s surgical tools and devices, it does so in signifi- cantly fewer operations while also eliminating the need for multiple machines and setups. Workpieces that would require as many as four operations on a lathe and four operations on a milling machine are completely machined on the multitask- ing Mazak in two. And for a specific hip broach currently done on other machines, the shop plans to move it to the Integrex 200-IV S, which will reduce the broach machining from 10 operations down to only one.
"Many designs of today’s existing surgical
tools are such that they could be improved in regards to ergonomics."
The Integrex 200-IV S at Oak View Tool is located in a cell along with a five-axis grinder. Having the two machines in close
proximity allows one machinist to operate both machines. All tools and devices the shop produces are ground, so once the Mazak machine completes machining operations, parts are quickly transferred to the grinder for finishing. In part processing, Oak View Tool machinists often
use the twin turning spindles on the Integrex 200-IV S for work support when machining the shop’s longer tools and devices, some of which are up to 24" (610-mm) long. The equal speed and synchronized C-axis motion of both spindles allow the machinists to chuck one end of the part in one spindle and the opposite part end in the second spindle as the machine’s milling spindle works on the part. Or the twin spindles are used for sequential operations, performing first Op/front side work in one spindle, then a coordinated part transfer to the second spindle for the second Op/back side work. Dahms’ observations of orthopedic surgical tools and devices in action and his consultations with surgeons and OEMs have led
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