FEATURE u Medical Equipment & Devices
Smithstown selects TRIUMPF TruPrint 2000 for its devices
Smithstown Light Engineering, based in Shannon, Ireland, has invested in a TRUMPF TruPrint 2000 3D printing system to further enhance its support for the country’s burgeoning medical device industry
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ounded in 1974, Smithstown Light Engineering started out with a workforce of four skilled toolmakers. During the
early 1990s, the company started specialising in medical device manufacturing and never looked back. Today, Smithstown employs over 140 people across three sites, two in Ireland and one in Poland, focusing on the provision of precision-engineered medical device and orthopaedic instrument/implant solutions, typically for hip and knee replacement procedures and cardiovascular delivery devices. Already offering a range of manufacturing
capabilities, including milling, turning, grinding and EDM, Smithstown was keen to add 3D printing to its portfolio, and set about creating an Additive Centre within a recently- constructed 30,000ft2
extension. “We worked for two years with Irish
Manufacturing Research, a technology and research organisation, to experience 3D printing and get a feel for what it could do in terms of its capabilities, limitations, advantages and disadvantages,” said Gerard King, Smithstown’s Managing Director. The aim was to provide an additive support
for Smithstown’s medical device customers, specifically for R&D work. “We looked at many potential machines
before designing our own benchmark and sending it to suppliers,” said Kevin Kelly, Manufacturing Engineer at Smithstown. “It was the quality of the benchmark produced by TRUMPF with its TruPrint 2000 that caught our attention. In addition, the volume of the machine was perfect for our needs, and the price was competitive.”
TRUMPF TRUPRINT Installed at the end of 2020, Smithstown is using its new TruPrint 2000 to produce printed parts from metal. The company’s new Additive Centre also houses a machine for printing polymer components. “Additive is ideal for medical work because of the complex geometries involved,” says Kelly. “Without 3D printing, several processes would be required, taking many hours. Additive also offers the potential for individual customisation, with obvious benefits for products such as implants.” Since installation, the machine has been
producing prototypes and samples for medical 28 July/August 2021 Irish Manufacturing
device customers in 17-4 and 316 stainless steel.
“In the medical sector it can take years
to move from the design and test stage to validated production, but we’re now in a position to help expedite this process and bring customer ideas to life,” said Kelly. “Upon reaching the production phase of current projects we could well need several 3D printing systems so that we can dedicate machines to a single material. We will not hesitate to invest in more machines if the demand is there.”
With its small 55µm diameter laser beam,
the TruPrint 2000 provides a high-quality printing result that impresses with its surface quality and level of detail. Two TRUMPF 300W fibre lasers deliver high productivity over the entire cylindrical build volume of 200mm x 200mm.
Among notable options that help to ensure the highest quality standards is melt pool monitoring. With this function, deviations in the laser metal fusion process are detectable early via sensors, and critical areas of the component can be visualised. Users can also monitor all weld pools in parallel.
BUSINESS STRATEGY Moving forward, Smithstown’s business strategy is to focus more on high-volume precision components, rather than simply
tooling and small batch parts. “Some of our competitors have 3D printers,
but the TruPrint 2000 definitely gives us an edge,” said Kelly. “Furthermore, we have a dedicated team of experts who can design parts specifically to leverage the benefits of additive manufacturing, thus helping us to minimise costs without compromising quality. Designing a part for additive manufacturing is quite different to designing a part for traditional machining.” Smithstown – which carries certifications that include ISO9001 (quality), ISO13485 (medical devices) and ISO14001 (environmental) – has recently secured several new projects that are driving the need for more staff recruitment. Alongside its investment in the latest manufacturing technologies, ongoing growth is assured at this forward-thinking business. “We are really happy with the quality and build speed of the TruPrint 2000, which is backed-up with good support from TRUMPF – they’ve listened to our needs throughout,” said King. “As a result, we’ve not experienced any unexpected issues whatsoever, which is impressive considering this is our first venture into additive manufacturing.”
TRUMPF Ltd.
www.trumpf.com
www.irish-manufacturing.com
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