For an orthopaedic instrument manufacturer and precision engineer, two CNC 5-axis milling machines have reduced lead times, increases production capacity and reduce set-up time by up to 50%.

Precision engineeers invest in 5-axis milling For an orthopaedic instrument manufacturer and precision engineer, two CNC 5-axis milling machines have reduced lead times, increases production capacity and reduce set-up time by up to 50%. Market-leading orthopaedic instrument manufacturer and precision engineer reduces lead times, increases production capacity and maintains its competitive edge through its latest investment in advanced 5-axis milling technology. Sheffield, UK-based precision engineers Eurocut, a subsidiary of the AIM listed Medical House (TMH), has recently invested in two Mikron UCP 600 Vario ProdMed milling machines.

The machines, installed within Eurocut's extensive manufacturing facility during Autumn 2006, are being used to help manufacture high-precision complex orthopaedic devices and instruments.

However the machines are mainly being used to produce equally complex, high-accuracy (and high-value) components for other manufacturing sectors - oil/gas, aerospace, automotive, motor sport, etc, through their newly formed subsidiary TMH Engineering.

* About Eurocut - Eurocut was established in 1988 and now employs around 80 people.

The company has historically specialised in the design, development and manufacture of high-quality instruments for use in Orthopaedic surgery - supplying complex customised individual instruments and complete systems to major Orthopaedic Implant companies worldwide.

Orthopaedic instrument design and manufacture accounts for approximately 80% of Eurocut's business - the remaining 20% derives from providing specialist, high-precision sub-contract manufacturing solutions to a diverse range of customers across an equally diverse range of industries through TMH Engineering.

* Manufacturing imperatives - in both its orthopaedic instrument and precision sub-contract operations there are similar manufacturing demands and imperatives, as follows.

i1 - Parts and components are manufactured from difficult to machine materials - stainless, titanium, alloys, 'exotics' (e g, Inconel), aluminium, etc.

2 - Parts are complex and are characterised by their intricate forms, profiles, detail, etc.

3 - Parts are typically required in low-to-medium volumes (sometimes one-offs).

4 - Delivery times/lead times are short.

5 - Part accuracy and surface finish requirements are stringent.

In response to these demands, TMH made its investment in the two Mikron UCP 600 machines.

* UCP 600 Vario - the UCP 600 Vario's are High-Performance Milling (HPM) machines with positional and simultaneous 5-axis capability.

The machines have 'built-in' automation - 30 position automatic tool changer (ATC) and seven pallet automatic pallet changers (APC) - both of which ensure maximum productivity and continuous machining (facilitating lights-out and unattended operations) for low-to-medium volume production.

The integrated automation capability of the machines helps reduce lead times and improves cost competitiveness.

The UCP 600's 5-axis capabilities clearly also help speed up production and ensure high precision and quality by shortening part cycle times and reducing time and resources spent on setting up, fixturing, etc - all critical in making customised part manufacture economically viable.

Eurocut has significantly reduced the number of set-ups and the time involved in job set up operations (by more than 50%) since it invested in the Mikron machines.

Irrespective of whether high, accurate material removal, interrupted cutting or fine finishing is required - the UCP 600 Vario machines with their StepTec high-performance, vector-driven HSK spindles (20,000 rev/min) can be relied upon to deliver.

Due to their integrated automation (ATC and APC) - the machines can run unattended - including 'lights-out', weekends etc.

However, to ensure that these productivity gains can be realised and to avoid problems such as workpiece and/or cutting tool damage due to poor chip evacuation and part contamination - the machines are equipped with sophisticated swarf management and chip removal systems.

For long production runs - laser tool measurement and inspection plus the machines' Remote Notification System (RNS), used to notify the operator when machining has been interrupted, come into their own and optimise productivity.

The machines are also supplied with Mikron SMART technology software to further optimise machining and ensure improved process reliability - by enabling the operator to make decisive interventions in the machining process in 'real time'.

Said Ian Townsend, chairman of TMH: 'We invest heavily in advanced machine tool technology - and to improve our productivity and performance we knew we needed 5-axis milling capability sooner rather than later.' He added: 'We visited Mikron's facility in Nidau, Switzerland as part of the selection process - and we liked the look of the UCP 600 Vario machines straight away.

There is a definite 'match' between our manufacturing requirements and the way we operate - and the machine's specification and capability.

That's why we ordered two.'.

* Additional Eurocut capability - in addition to the 5-axis UCP 600 machines Eurocut (TMH) has (over recent years) made significant investment in EDM and other machine tool technologies.

The company has an impressive EDM manufacturing cell that comprises five state-of-the art Charmilles wire cut and die-sink machines.

Eurocut/TMH also has a comprehensive range of lathes, turning centres, 3- and 4-axis milling machines, CNC grinding machines, CMM equipment and a DTM Sinterstation 2500 rapid prototyping machine.

This machine enables the ultra-fast generation of prototypes without the lengthy and costly lead time normally associated with new product design and development - and has helped Eurocut strengthen its relationships with customers involved in R+D projects.

The company is vertically integrated.

As well as manufacturing high-quality instruments and devices, Eurocut/TMH also provides in-house design, proto-typing, electro-polishing, heat treatment and a comprehensive range of finishing services that include - laser marking, engraving, passivation, packaging and labelling.

This means that Eurocut/TMH can provide a total solutions package to its customers - from design right through to delivery...and everything in-between.