Medical orthopaedic component surface finishing

Surface finishing techniques play a vital role in the development of both medical devices and orthopaedic implants. No medical equipment can shine better without being finished efficiently by choosing the right surface finishing tool. For orthopaedic implants, there is a high demand for dimensional accuracy that can be achieved precisely by using lapping and polishing processes. Medical devices also have intricate parts such as blades that needs to be finished perfectly to achieve professional performance. There is no chance of risk in these devices in terms of dimensions, sharpness, roughness, alignment, etc. It, therefore, requires an accurate measurement that is possible using the surface finishing techniques mentioned above.

The Kemet Process Development Laboratories have been successful in developing Special Purpose Polishing Machines for a wide range of Medical Implants.  Kemet’s latest development, the KemiSphere II, a bench top spherical/ball lapper/polisher, laps and polishes spherical forms to better than five microns roundness with a mirror finish. The simple 2 stage process provides an extremely economical repeatable way of processing spherical forms to a huge variety of surface finishes and can process a range of different materials either to be lapped as an individual component, or to match lap spherical forms together. The machine can process all joint sizes and materials up to 60mm in diameter (or 100mm with the floor-standingversion). Kemet also offer to prove a process within their testing labs producing test data and samples so that all questions can be answered prior to even ordering a machine. This also means that machines are typically delivered pre-programmed ready for use whatever the application.

With tibial tray and hip manufacture, the majority of production costs are for process consumables and, as a manufacturer of these, Kemet are ideally placed to help reduce them. Perhaps more importantly, however, Kemet’s expertise in surface finishing enables them to develop new processes and consumables, aimed at increasing productivity and reducing the cost per part. The improvements to the process can far exceed the cost attached to introducing new consumables, be it less rework, faster throughput or even lower consumption. The Kemet Tibial Polishing Cell has been specifically developed for finishing large production quantities of replacement Knee parts, such as Tibial Trays. A typical Cell contains Kemet Smoothing, Polishing and Cleaning Systems.

Manufacturers now have the added benefits of improved product quality, greatly reduced costs and faster production. All Kemet Polishing Systems, be they small manual processes or large fully automated cells are serviced and supported by Kemet. The Company is also a major manufacturer of polishing consumables and as such is able to take full responsibility for all aspects of production relating to one of its finishing processes. Currently, all process development work for customers is being carried out free of charge.

Kemet’s ability to develop, supply and support such processes has made the Company a global leader in this technology. As well as precision surface finishing, Kemet also offer;

• Ultrasonic Cleaning Tanks ranging from 40 to 160 litres with more than 400 high-performance formulations to choose from.
• Aqueous Cleaning Fluids with validation standards of ISO 19227-2018 and biocompatibility standards of ISO 10993-18, ideal for the medical industry.
• Passivation lines that comply with ISO 7 clean room.
• Vacuum Solvent Cleaners which have minimal loss of solvent, significantly reducing process cost.

Contact Kemet on +44 (0) 1622 755287 or Sales@Kemet.co.uk to arrange Lapping or Polishing trials, so Kemet can find the ideal solution for you.