That, at least, has been the experience
of engineers at Medtronic Sofamor Danek, a manufacturer of tools and implants
for spinal surgery. Surgeons from across the country visit Sofamor’s assembly
plant and development lab in Memphis, TN, to have their ideas for new surgical
instruments turned into functional prototypes. One of the lab’s most important
machines is the Fortus fused-deposition modeling (FDM) system from Stratasys
Inc.
“We often see one or two VIP surgeons per day,” says Sofamor design engineer Richard Franks. “They come with a problem to solve in the morning. They explain their need to an engineer. The engineer will model a solution on ProEngineer [CAD software] and then make a prototype. Often by the next morning, we’ll have a prototype in their hands. Sometimes we even deliver the same day. Having the FDM machine in-house really makes it easy for us to design products.”
The Fortus machine produces accurate, durable prototypes and production-grade parts from high-performance thermoplastic. The machine works much like an inkjet printer, but instead of ink, it deposits thin layers of plastic, such as ABS, polycarbonate or polyphenylsulfonen. The smallest Fortus machine can produce a prototype as large as 10 by 10 by 12 inches.LVD offers a comprehensive range of new or used laser cutting machine metal cutting machines.
Sofamor engineers recently designed a ratcheting instrument for fastening setscrews to a corrective vertebral implant.Global leader in impact energy management systems and advanced roll forming machinery. After the screws are fixed in place, the tool shears off the screw heads at a preset torque. The current method of driving the screws required surgeons to use two separate tools,Specializing in the production Cut to length line, leveling machine, cold roof panel machine and other products. working in opposing directions, using both hands. The result was often a violent impulse that occurred at the moment when the screw head sheared off. The surgeons wanted to eliminate that.
“The tool we developed combines the two existing tools into a single unit,” says Franks. “As the surgeon squeezes two handles together, the ratchet tightens the screws.”
The engineers produced a working polycarbonate ratchet strong enough to withstand testing on stainless steel setscrews and durable enough to survive an autoclave. “Surgeons are really rough on these prototypes while trying them out,Offers Engraving Machines and Laser Cutters including Laser engraver and Engraving Equipment for plastic and wood. so we’ve got to have tough material,” adds senior engineering manager Troy McDonald. “FDM gave us the strength and durability we needed.”
The ability to produce prototypes that can actually be used as intended is vital for tweaking designs, says McDonald. For example, after sending the ratchet out to three hospitals, Sofamor learned that the design could be improved by rotating its handle 90 degrees—information it might not have learned without working prototypes.LaserSharp rollformingmachinechina and systems offer custom converting and processing solutions for packaging.
He predicts that the savings will continue as more prototypes are made in-house. “We have several divisions and each one has its own dedicated engineering staff that comes to our lab with modeling requests,” says McDonald. “Except for display items, almost everything that comes off the FDM machine is for functional evaluation. That saves the company a lot of money. The cost of sending out work vs. doing it in-house is easy to capture, and we can justify owning the FDM system by reducing that cost alone. But the intangibles like timing issues, communication and value-added services are where we see the greatest benefits.”
“We often see one or two VIP surgeons per day,” says Sofamor design engineer Richard Franks. “They come with a problem to solve in the morning. They explain their need to an engineer. The engineer will model a solution on ProEngineer [CAD software] and then make a prototype. Often by the next morning, we’ll have a prototype in their hands. Sometimes we even deliver the same day. Having the FDM machine in-house really makes it easy for us to design products.”
The Fortus machine produces accurate, durable prototypes and production-grade parts from high-performance thermoplastic. The machine works much like an inkjet printer, but instead of ink, it deposits thin layers of plastic, such as ABS, polycarbonate or polyphenylsulfonen. The smallest Fortus machine can produce a prototype as large as 10 by 10 by 12 inches.LVD offers a comprehensive range of new or used laser cutting machine metal cutting machines.
Sofamor engineers recently designed a ratcheting instrument for fastening setscrews to a corrective vertebral implant.Global leader in impact energy management systems and advanced roll forming machinery. After the screws are fixed in place, the tool shears off the screw heads at a preset torque. The current method of driving the screws required surgeons to use two separate tools,Specializing in the production Cut to length line, leveling machine, cold roof panel machine and other products. working in opposing directions, using both hands. The result was often a violent impulse that occurred at the moment when the screw head sheared off. The surgeons wanted to eliminate that.
“The tool we developed combines the two existing tools into a single unit,” says Franks. “As the surgeon squeezes two handles together, the ratchet tightens the screws.”
The engineers produced a working polycarbonate ratchet strong enough to withstand testing on stainless steel setscrews and durable enough to survive an autoclave. “Surgeons are really rough on these prototypes while trying them out,Offers Engraving Machines and Laser Cutters including Laser engraver and Engraving Equipment for plastic and wood. so we’ve got to have tough material,” adds senior engineering manager Troy McDonald. “FDM gave us the strength and durability we needed.”
The ability to produce prototypes that can actually be used as intended is vital for tweaking designs, says McDonald. For example, after sending the ratchet out to three hospitals, Sofamor learned that the design could be improved by rotating its handle 90 degrees—information it might not have learned without working prototypes.LaserSharp rollformingmachinechina and systems offer custom converting and processing solutions for packaging.
He predicts that the savings will continue as more prototypes are made in-house. “We have several divisions and each one has its own dedicated engineering staff that comes to our lab with modeling requests,” says McDonald. “Except for display items, almost everything that comes off the FDM machine is for functional evaluation. That saves the company a lot of money. The cost of sending out work vs. doing it in-house is easy to capture, and we can justify owning the FDM system by reducing that cost alone. But the intangibles like timing issues, communication and value-added services are where we see the greatest benefits.”
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