According to statistics, the number of artificial bone implants continues to increase. In 2010, one million artificial hip and knee joints were implanted in the U.S. Forecasts expect this number to exceed four million by 2030.
German-based Implantcast Corp. produces titanium implants on turning-milling centers equipped with Siemens Sinumerik 840 computer numerically controlled (CNC) units. The machines are suitable for generating both complex single parts and large production runs. The 840D sl is capable of producing implants and associated instruments that are cut perfectly to the bone structure with the help of computer tomography (CT) or magnetic resonance imaging (MRI).
Bone rasps are supplied to orthopedists with the joint implants for the proper preparation of the bone.
For a single part production, operators use the Sinumerik setup functions for fast machine configuration. The CNC user interface provides self-explanatory icons that can be pre-set as popular, “most used” keys. Many intelligent functions are available that assist in measuring tools and making parts. These measurement functions help in overall process and product quality assurance.
The controller provides a comprehensive range of turning and milling cycles. Operator functions and process cycles appear on-screen as animations so technicians can easily recognize next-step procedures.
Sinumerik 840D sl with the Sinumerik Operate user interface: Dual-channel representation in the CNC simulation brings transparency to the programming and the set-up, even for complex implants.
In addition, the controller has a program simulation that shows the stock removal process in virtual 3D. The images depict the cutting actions and the expected machining time before the production of a single implant.