Graphical output of measurement data shows the magnitude and direction of measured deviations from the nominal form. Metrology measurements of medical devices used for long-term process control is just as important as quality control on individual parts.
Variety, small lots, and ever-tighter tolerances characterize his business. “Twenty percent of what we do on a monthly ba- sis is a new part,” he says. “Some months, 35% of what we are processing is brand new.” That includes materials new to the machining company, such as processing PEEK plastics. “Our established processes for machining, inspecting, and handling of implantable PEEK materials are tightly controlled,” says Jeff Hicks of Micropulse. “Manufacturing equipment and trained personnel have been dedicated to processing implantable PEEK to ensure that the product is consistently produced and handled according to specifications. In addition, the product is transported throughout the facility in visually unique containers. This provides notification to all employees that special handling is required in order to prevent contamination of the product.”
“Many aerospace manufacturers have added medical because there are many similarities between the two industries.”
Dedicated quality technicians will typically run exhaustive first-article inspections for part approvals. They also check first runs of every new lot to ensure process stability after machine setup. Two quality labs are set in strategic locations in their 100,000 ft² (9290 m²) facility, with one CMM and optical
comparators set-up on the shop floor itself. Their CMMs are also equipped only with touch probes and scanning analogue probes. Metrology at Micropulse is not for dedicated technicians alone. “The machinists and quality technicians both have access to the same inspection equipment. Machinists are able to use the appropriate inspection tools to verify product as it is being manufactured,” explained Hicks. “Inspection activities for prototype devices, which are manufactured in a dedicated cell, are primarily performed by prototype personnel.” Of course, the goal is to not burden operators with quality checks at locations distant from their machine. Micropulse uses dedicated expediters to track lots as they move through operations and physically move the material from machine to machine and into metrology stations. This keeps machines humming and operators dedicated to what they know best. “Implantable devices are becoming more common and there are more manufacturers of them,” says Jamie Murray, Senior Applications Engineer at OGP. “Because of the critical nature of implantable parts, manufacturers are doing more measurements