Custom Manufacturing of a Medical Device for the Surgical Industry
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A mini joint distractor is a unique device that surgeons use for distraction and compression of bone cutting and fusion sites. At Precision Metal Machining, Inc., we were asked to manufacture these devices—which already had design issues—in a very short window of time. During the distractor's design, many issues arose regarding the intent of the product. Using our knowledge of material, form and fit, and design for manufacturability, we worked along with the customer's design engineer to improve functionality and durability. Suggestions regarding materials, hardware, and metal fatigue prevention made by us were subsequently incorporated into the design, and are still in use today. Still, the design went through numerous iterations during the early stages for various reasons. Our staff, however, drove the project to acceptance, even though the delicate final assembly required a degree of force during use.
Utilizing CNC lathes and mills as well as manual mills, the complex assembly components were machined out of 17-4 and 465 SS as well as aluminum to tolerances of ±0.0005". Components were then blasted, passivated, polished to a matte finish, assembled by welding, and marked via laser. Final inspections were conducted for dimensional accuracy, functionality, and torque. Very tight delivery requirements had to be met so the customer could test the new design features before committing to the production order. Working to ISO 13485:2003 standards, we delivered the prototypes in two weeks, completed the initial order in only four weeks, and completed the total order of 225 pieces in a short six weeks.
This project was a remarkable confluence of customer service, engineering, design for manufacturability, and material expertise that resulted in an extremely satisfied customer. To learn more, contact us directly.
Mini Joint Distractor Project Highlights
- Project Name
- Mini Joint Distractor
- Project Description
- The Mini Joint Distractor is a unique device that surgeons use for distraction and compression of bone cutting and fusion sites.
- Capabilities Applied/Processes
Machining of Complex Assembly Components
Functionality & Durability Improvement
- Equipment Used to Manufacture Part
- CNC Lathe, CNC Mill, Welding, Assembly, Manual Mill, Blasting, Polishing, Passivation, Laser Marking
- Tightest Tolerances
- Material Used
- 17-4SS, 465SS, Aluminum
- Material Finish
- Matte finish
- Industry for Use
- In Process Testing/Inspection Performed
- Dimensional Inspection, Functionality, Torque
- 225 pieces
- Delivery/Turnaround Time
- Prototypes – 2 weeks. Initial order (50 pieces) – 4 weeks. Balance – 6 weeks
- Delivery Location
- Standards Met
- ISO 13485:2003
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