Facial titanium implants
For orthopedic implant industries
GPAINNOVA’s client is Hybrid Technologies (formerly named MDS), an Armenian hybrid laboratory with almost 30 years of experience in the dental sphere. The company was established shortly after the end of the Nagorno-Karabakh conflict to respond to the needs of those injured during the war. In the beginning, the laboratory produced titanium articular heads, implants, and prostheses, which were extremely necessary for civilians and soldiers with problems related to the maxillofacial, craniocerebral, and mobile apparatus.
To adopt the Selective Laser Melting (SLM) technology, Hybrid Technologies partnered with Sisma Laser, an organization that combines modern and independent production capabilities with a wealth of highly specialized human resources. This partnership aims to guarantee the best product quality and meet the changing market requirements.
THE PROBLEM
The company was determined to enhance the later stages of processing by achieving a mirror surface on implants without damaging them. Traditional methods, such as manual or mechanical polishing, presented certain drawbacks and challenges that could impact the quality and efficiency of the polishing process. Previously, Hybrid Technologies utilized manual and mechanical polishing methods, which proved to be inefficient, time-consuming, and expensive. Manual polishing was carried out by in-company technicians, and the polishing step alone took up to 120 minutes per piece.
An additional challenge was the type of metal used in the implants: high-quality medical titanium, meeting international ISO-13485 and ISO-5832-3 standards. Titanium is a relatively hard metal compared to most common materials, making achieving a mirror finish more time-consuming. However, titanium is also prone to scratching, despite its excellent strength and durability. Applying excessive pressure during polishing can create scratches on the surface that are difficult to remove and may necessitate additional polishing steps.
THE GOAL
Hybrid Technologies sought a post-processing solution to enhance production efficiency, reduce lead times, and lower production costs associated with the current manual surface finishing process. The customer’s specific requirement was to treat facial implants that demanded different surface qualities based on their application. Maxillofacial implants needed a smooth surface, while cranioplasty parts required a mirror-finished surface to fulfill their intended function. Therefore, the company aimed to achieve a significant roughness reduction for facial implants and a mirror surface finishing for cranial implants, achieving a smoothness reduction of up to 0.05 μm (1.97 microinches).
THE SOLUTION
GPAINNOVA not only successfully automated the polishing process for titanium facial implants but also reduced the process duration to less than half. Through the use of the DryLyte Technology, the laboratory was able to replace the previous three-step process, which included an abrasive station, manual polishing, and a final touch for brightness, with a streamlined two-step workflow that only involved an abrasive station and automated DLyte surface finishing.
As a result, the client significantly increased its production efficiency. Based on a processing time of 50 minutes and an estimated total time of 4 minutes for loading and unloading the holders, the total process time was reduced to 54 minutes. With a single shift, the daily output reached 8 craniocerebral implants, resulting in an annual production of 2,000 units over 250 working days.
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