manual deburring operations. Instead, Riser writes a 30-second trimming operation that follows along the edges removing burrs. As a result, very little has to be done to the part once it has been machined. Simulation: Riser uses Mastercam’s Verify
simulation module to make sure there are no interferences that could break a tool or dam- age a part. If the part program does not verify correctly in simulation, then it is impossible to make a good part on the machine. STL Compare: Tis routine compares STL
data taken from Mastercam’s model of the final machined part directly with the Solid- Works model. It is very much like inspecting the finished part before it has been manu- factured. Riser said, “I compare 100% of the parts I program with the SolidWorks model. I can look at this comparison and know instantly if I have it right or wrong within 0.0001" [0.00254 mm]. Tis is hands-down my most beneficial tool in the soſtware.” Postprocessor: Finally, Riser has worked
closely with nearby Mastercam vendor CAD/ CAM Technologies (Pendleton, IN) to refine his postprocessors to the point where there is very little to do at the machine except set up the part and run the program. Riser said, “Tere is no way we could
do some of the things we do for our surgi- cal customers without Mastercam. I have been programming with it for eight years and I have seen the toolpaths improve with each release of the soſtware. Today, the number of toolpaths I need to make a part has been greatly reduced. Tat is because the quality and reliability of the new toolpaths have improved so much. Tey do so much more and we need those improvements to keep getting better at what we do.”
Mastercam’s Verify simulation feature visually establishes that the material to be removed from the PEEK spacer is within limits, as dictated within the implant’s model.
look at things differently—some operate under a microscope and others do not. So they need different instruments to satisfy their different surgical techniques. Elsbury considers it a win when he can get them to agree on two standard versions of a new implant or instrument. Because of their familiarity with the product development
Taking It On The Road Every week Andy Elsbury gets on an airplane and flies out
to meet with a different surgeon than the week before. Tese discussions range from new product concepts to getting feedback on product design concepts that other surgeons have proposed. He said, “If we can get five different surgeons happy with
a product, then it should be a good one. It could take five or more weeks to get all the input I need from my design sur- geons before I can pass it along to my design engineers. Ten we can go into prototyping.” It is a rare event when all of the consulting surgeons agree on a single product configuration. Tat is because they literally
process, the surgeons know how easy it is to get customized implants and tools and they don’t hesitate to ask for them. All of this consultive selling and collaborative development translates into a steadily increasing flow of CNC programming requirements, which make it all the more likely that Beau Riser will be working closely with Mastercam reseller CAD/ CAM Technologies to identify the features in the latest release of the soſtware that will allow him to simultaneously keep pace with standard product manufacturing, special requests, and aggressive new product development.
Feature edited by Yearbook Editor Michael Anderson from information provided by CNC Software Inc.
Medical Manufacturing 2014 67
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