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ActOn Case Studies
Cost Efficient Solution for Deburring 1.44 Million Surgical Instruments per Year
The medical device industry continually strives to improve precision, quality, and efficiency in its products. For a U.S. based manufacturer specialising in orthopedic surgical tools, the challenge lay in optimising the finishing process for stainless steel saw blades. These saw blades, crucial for orthopedic trauma surgeries, require flawless surfaces for enhanced performance and safety. GPAINNOVA’s DryLyte technology offered an innovative, cost-effective, and environmentally friendly solution to meet the manufacturer’s needs.
Project Background
Customer was looking into options to optimise the process of deburring surgical instruments, such as the saw blades. These components are vital tools in orthopedic trauma surgeries. To perform effectively, they need ultra-sharp teeth for precision, smooth burr-free surfaces to avoid contamination, and consistent thickness to ensure control during operations.
The client’s manufacturing process involved laser-cutting the blades, which left burrs and rough edges that could trap debris or bacteria. Traditional liquid electropolishing was used to address these issues, but the process presented challenges:
- High Costs: The outsourcing of polishing led to significant expenses in both production and hazardous waste management.
- Inconsistencies: Uneven finishes resulted in a higher scrap rate.
- Environmental Impact: The process relied on hazardous chemicals, contributing to a large environmental footprint.
Faced with the need to produce 700,000 saw blades annually, the client sought a faster, cost-effective, and sustainable alternative.
The Aim
The goal was to implement a solution that would:
- Ensure precise burr removal for smooth, sterile surfaces.
- Maintain consistent thickness for control and stiffness.
- Achieve scalable, high-volume production.
- Minimise environmental impact and waste.
An Efficient Solution for Deburring Surgical Instruments
GPAINNOVA’s team developed a comprehensive solution using DryLyte technology, a dry media-based electropolishing process. This innovative approach avoids the hazardous chemicals and waste associated with traditional liquid electropolishing.
The project began with a batch of stainless steel saw blade samples in various sizes. A thorough analysis was conducted of the material, surface conditions, and desired finish.
A customised dry media electrolyte was chosen for deburring surgical instruments and achieving a smooth surface finishing. Also tailored fixtures were built to hold the blades securely during processing. These fixtures were tailored to:
- Avoid shadowing for uniform finishing.
- Prevent impact damage.
- Maximise the number of parts processed per cycle.
The DLyte PRO500, a compact, high-capacity machine designed for mass production, was chosen for the project. This equipment can process up to 120 blades per cycle, ensuring consistent results and high throughput.
Extensive trials tested various parameters, including process times ranging from 1 to 15 minutes. The most effective setup used a single deburring step with a mix of large and small macro-porous media particles.
The DLyte PRO500
The DLyte PRO500 is a cutting-edge dry electropolishing machine designed to meet the stringent demands of the medical industry. This advanced system utilises GPAINNOVA‘s patented DryLyte technology, which employs dry media to achieve precise, uniform surface finishing without the need for hazardous chemical baths. Ideal for stainless steel surgical tools, such as orthopedic saw blades, the DLyte PRO500:
- ensures burr-free surfaces,
- enhanced corrosion resistance,
- biocompatibility—critical factors in medical applications.
Its high capacity, with the ability to process up to 120 pieces per cycle, and reduced operational costs make it a game-changer for mass production. Additionally, its eco-friendly design eliminates the need for liquid waste disposal, aligning with sustainability goals while ensuring consistent quality and efficiency in manufacturing.
The Result
The implementation of the DLyte PRO500 system delivered significant improvements:
- Processing time: 4 minutes per batch of 120 blades.
- Material removal: 0.01 grams per blade, with an average blade weight of 30 grams.
- Media capacity: a 210-liter media bowl could process up to 500,000 blades before replacement.
- Daily output: 5,760 blades per shift.
- Annual capacity: 1.44 million blades, far exceeding the client’s requirement of 700,000 units
Interested in Finding out More?
To learn more about the DLyte Dry Electropolishing Technology click here. For further information regarding the finishing process or to request a free Trial email our technical team.
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