3D printer supports medical device market

Smithstown Light Engineering, based in Shannon, Ireland, has invested in a Trumpf TruPrint 2000 3D printing system to further enhance its support for the country’s burgeoning medical device industry. The first machine of its type in Ireland, the TruPrint 2000 is now busy producing prototypes and samples for a variety of customers in 17-4 and 316 stainless steel.

Founded in 1974, Smithstown Light Engineering started out with a workforce of four skilled toolmakers. During the early 1990s, the company moved towards specialising in medical device manufacturing and never looked back. Today, Smithstown employs 141 people across three sites, two in Ireland and one in Poland, focusing on the provision of precision-engineered medical device and orthopaedic instrument/implant solutions, typically for hip and knee replacement procedures and cardiovascular delivery devices.

Already offering a range of manufacturing capabilities, including milling, turning, grinding and EDM, Smithstown was keen to add 3D printing to its repertoire, and set about creating an Additive Centre within a recently constructed 30,000 sq ft extension.

“We worked for two years with IMR [Irish Manufacturing Research], a technology and research organisation, to experience 3D printing and get a feel for what it could do in terms of its capabilities, limitations, advantages and disadvantages,” explains managing director Gerard King.

The aim was to provide an additive support role for Smithstown’s medical device customers, specifically with regard to R&D work.

“We looked at many potential machines, before designing our own benchmark and sending it to suppliers of interest,” says Kevin Kelly, manufacturing engineer. “It was the quality of the benchmark produced by Trumpf, using their TruPrint 2000, which caught our attention. In addition, the volume of the machine was perfect for our needs and the price was competitive.”

Smithstown is already using its new TruPrint 2000 to produce printed parts from metal. The company’s new Additive Centre also houses a machine for printing polymer components.

“Additive is ideal for medical work because of the complex geometries involved,” says Kelly. “Without 3D printing, several processes would be required, taking many hours. Additive also offers the potential for individual customisation, which has obvious benefits for products such as implants.”

Since installation, the machine has been busy producing prototypes and samples for medical device customers in 17-4 and 316 stainless steel.

“In the medical sector it can take years to move from the design and test stage, to validated production, but we’re now in a position to help expedite this process and bring customer ideas to life,” explains Kelly. “Upon reaching the production phase of current projects we could well need several 3D printing systems so that we can dedicate machines to a single material. We will not hesitate to invest in more machines if the demand is there.”

With its small 55 µm diameter laser beam, the TruPrint 2000 provides a high-quality printing result that impresses with its surface quality and level of detail. Two Trumpf 300 W fibre lasers deliver high productivity over the entire cylindrical build volume of 200 mm diameter by 200 mm high.

The TruPrint 2000 also enables the industrial processing of amorphous metals. These metals feature exceptional strength combined with high elasticity, corrosion resistance and biocompatibility. Wall thicknesses can then be reduced and bionic structures used in component design, resulting in lower component weight and shorter production time.

Among notable options that help to ensure the highest quality standards is melt pool monitoring. With this function, deviations in the laser metal fusion process are detectable early via sensors, and critical areas of the component can be visualised. Users can also monitor all weld pools in parallel.

Moving forward, Smithstown’s business strategy is to focus more on high-volume precision components, rather than simply tooling and small-batch parts.

“Some of our competitors have 3D printers, but the TruPrint 2000 definitely gives us an edge,” says Kelly. “Furthermore, we have a dedicated team of experts who can design parts specifically to leverage the benefits of additive manufacturing, thus helping to minimise costs without compromising quality. Designing a part for additive is quite different to designing a part for traditional machining.”

Smithstown – which carries certifications that include ISO9001 (quality), ISO13485 (medical devices) and ISO14001 (environmental) – has recently secured several new projects that are driving the need for more staff recruitment. Alongside its investment in the latest manufacturing technologies, ongoing growth is assured at this forward-thinking business.

“We’re really happy with the quality and build speed of the TruPrint 2000, which is backed-up with good support from Trumpf – they’ve listened to our needs throughout,” concludes King. “As a result, we’ve not experienced any unexpected issues whatsoever, which is impressive considering this is our first venture into additive manufacturing.”

Trumpf will demonstrate its 3D printing systems at TCT3Sixty (28-30 September, Birmingham NEC). Visitors to stand F28 will see how 3D printing systems are shaping the future of manufacturing technology. Trumpf offers both relevant laser technologies for additive manufacturing from a single source: laser metal fusion (LMF) and laser metal deposition (LMD). Different industries and components have varied requirements, which is why Trumpf offers such flexible production solutions. New to the range is the TruPrint 3000 3D printing system, where the company says that production set-up is easily adapted to the requirements of the customer or application.

For further information
www.trumpf.com

Cancer centre benefits from XYZ VMC

The National Centre for Eye Proton Therapy, part of The Clatterbridge Cancer Centre NHS Foundation Trust’s Wirral campus, is a world leader in the treatment of rare eye cancers. The advantage of proton treatment is that the penetration depth of the 60 MeV proton beam can be controlled and only has a maximum range of 31 mm in water, making it suitable for treating any position within the eye and, in many cases, preventing the complete removal of a patient’s eye.

Patients require four treatments over four consecutive days that each take just 20 minutes. Key to the success of that treatment is a small brass component called a collimator, which is tailor-made to shape the beam to cover a specific tumour, while protecting the surrounding area. These collimators are now being machined using a new XYZ 500 LR vertical machining centre, in a cycle time that is 95% shorter than before.

Prior to treatment, a patient has the affected eye scanned to precisely identify the size and position of the tumour. Following conversion of the scan into a DXF file, a Siemens CAD reader generates tool paths for the XYZ 500 LR. From receiving the scanned data to finished part now takes between 15 and 20 minutes (against more than two hours previously), with less than seven of those minutes actual machining time.

This significant time saving has two major benefits. First, it frees-up time in the workshop to carry out other tasks, and second, on those occasions where a quick turnaround is required, it is possible to complete machining of the collimator in the time it takes the radiographer to set-up the proton beam machine and prepare the patient for treatment.

For further information www.xyzmachinetools.com

Entrepreneurialism is alive and kicking

Mills CNC, the exclusive distributor of Doosan machine tools in the UK and Ireland, has recently supplied ECAM Engineering with a new NHP 6300 horizontal machining centre.

Installed at the company’s 20,000 sq ft facility, it is the first horizontal machining centre acquired by the company in its 52-year history, as well as its first Doosan machine tool investment.

The arrival of the machine has not only increased ECAM’s machining capacity but also its production capabilities and will, over time, improve the company’s operational efficiencies and productivity levels.

Says ECAM’s managing director, Phil Arme: “We have a number of three-axis vertical machining centres at our disposal and use them to machine precision components, made from steel plate of varying thicknesses, that have previously been through our in-house steel profiling and fabrication processes. The arrival of the new NHP 6300, with its twin-pallet configuration and B-axis table, will enable us to machine these parts quicker and more efficiently. Furthermore, the new machine’s rigidity, large working envelope and BT 50 spindle technology provide significant opportunities for us to secure new contracts that involve the machining of larger and heavier components.”

The NHP 6300 supplied to ECAM includes a 37 kW/15,000 rpm BT50 spindle, a 60-tool servo-driven ATC and the latest Fanuc 31i control. Further features include roller LM guideways, a B-axis table that rotates in increments as small as 0.0001°, twin (630 mm) pallets, rapids of 60 m/min and axis travels of 1050 x 900 x 1000 mm.

Says Arme: “In the near future the machine will be used to machine steel components, often with intricate details and features, to high precision and tight tolerances.”

For further information
www.millscnc.co.uk

Three shows together in one place

Subcon 2021 (14-16 September, Birmingham NEC) is free to attend for anyone working in UK manufacturing and engineering, with visitors also gaining access to two further co-located events: The Engineer Expo and – new for 2021 – the Manufacturing Management Show (MMS). The Engineer Expo provides UK engineering professionals with the latest in-house manufacturing and design solutions alongside cutting-edge developments in advanced engineering technologies.

MMS supplies attendees with everything they need to know about running a successful manufacturing site under one roof. From maintenance and materials handling, through to continuous improvement, skills, IT and health and safety, MMS showcases a multitude of topics curated specifically for the UK’s senior manufacturing leaders.

For further information www.theengineer-expo.co.uk, www.manufacturingmanagementshow.co.uk

Get set for Subcon 2021

Subcon returns to support in-person networking as the UK manufacturing sector prepares for a post-pandemic future. Next week (14-16 September), Subcon will take place at the Birmingham NEC for the 44th time, heralding a much welcome return to business events and reinforcing the value of meeting face to face for the UK’s manufacturing and engineering sectors.

Subcon is the UK’s leading manufacturing supply chain show and its return as an in-person event comes at a pivotal time as UK manufacturers of all sizes recover from the impact of Covid-19, adjust to operating outside the EU and face a myriad of challenges and opportunities. The sector’s appetite for doing business in-person could not be stronger: the show’s headline sponsors are IAMP and SCS Concept Group, while over 150 companies will exhibit, including Hoffman Group UK, Wilson Process Systems and Oldham Engineering.

For further information www.subconshow.co.uk