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ActOn Case Studies
Revolutionising Surgical Instrument Cleaning with Advanced Surface Finishing Solutions
In the highly demanding field of surgical instrument cleaning and manufacturing, achieving impeccable quality is not just desirable—it’s essential. Manufacturers face the dual challenge of ensuring that their products meet stringent standards for cleanliness, durability, and biocompatibility, while also optimising efficiency and cost-effectiveness. This blog delves into how a European manufacturer of stainless steel surgical instruments transformed their production process by adopting a cutting-edge surface finishing technology.
Project Background
Surgical instruments, ranging from scissors and clamps to endoscopes and dental tools, must have a flawless surface finish. This is critical not just for aesthetics but for functional reasons such as reducing the risk of bacterial contamination and ensuring corrosion resistance. Traditional finishing methods, often reliant on manual processes, are time-consuming, inconsistent, and environmentally taxing. This manufacturer sought a solution that could deliver consistent, high-quality finishes with reduced lead times and lower costs.
Solution: Implants and Surgical Instrument Cleaning
To address these challenges, GPAINNOVA introduced an advanced surface finishing process tailored specifically for stainless steel surgical instruments. The goal was clear: achieve a mirror-like finish with significant reduction in surface roughness, while eliminating defects like burrs and milling lines. This would not only enhance the cleanliness and corrosion resistance of the instruments but also extend their lifespan.
Finishing Trials and Process Optimisation
The manufacturer collaborated closely with GPAINNOVA’s team to conduct extensive trials. The process involved preparing a batch of surgical instruments with an initial surface roughness (Ra value) between 0.3 and 0.15 microns. The objective was to reduce this roughness to below 0.2 microns and develop an efficient surgical instrument cleaning process. The process department recommended an electrolytic media process, using custom-designed fixtures and the DLyte PRO500 machine—a compact, high-capacity machine ideal for mass production.
The DLyte Process Benefits
The DLyte technology not only meets but exceeds industry standards. It achieves a high-quality finish across a wide range of metals and alloys, including stainless steel, cobalt chrome, and titanium. The process is highly precise, preserving the geometry and tolerances of the instruments while significantly improving corrosion resistance and biocompatibility.
Surgical Instrument Cleaning Process – Cost Efficiency and Environmental Benefits
One of the most impressive aspects of this new process was its cost-effectiveness. The operational expenditure (OPEX) was calculated at just €0.3 per part, with capital expenditure (CAPEX) at €0.7 per part over five years. This marked a substantial reduction in production costs—over 60% savings compared to traditional methods. Additionally, the process was more environmentally friendly, with easy waste management and a reduced footprint.
Results
The finishing process was refined into a two-step procedure. First, a 45-minute smoothing phase using microporous particles, followed by 15 minutes of microfinishing with gel particles. This resulted in a final surface roughness below 0.2 microns and minimal material removal. The process was highly efficient, handling 96 pieces per batch with a total cycle time of 64 minutes.
The manufacturer was able to boost daily output to 670 instruments, leading to an annual production of 167,500 units—all with a single shift operation. This represented a significant leap in both efficiency and consistency, setting a new standard for quality in the industry.
Interested in Finding out More?
If you would like to learn more about the process steps and technology used, you can request the Surgical Instruments Case Study. You can also email our technical team for technical support with your fashion and jewellery components.
