Maldon-based
OrthoSolutions designs, develops and manufactures implants and instruments used in surgical repairs of the foot and ankle, and in support of the design process, the company works closely with specialist surgeons. The foot is a complex structure comprising 33 joints, 26 bones and more than 100 muscles, tendons and ligaments that all work together to bear weight, allow locomotion and transmit force. Fractures and other injuries are varied and complex, so OrthoSolutions offers a wide range of products that provide a solution for the majority of debilitating conditions that occur within the foot and ankle complex.
After in-house design of a new product has been completed, the first stage of the prototyping process involves 3-D printing a plastic model. Next a steel prototype is manufactured, which in the past was sub-contracted out, adding up to 16 weeks to the lead time. A further complication was that surgeons would often ask for small design changes or improvements, which could double the delay.
So to speed up the prototyping phase, OrthoSolutions has invested in a new, purpose-built production facility and purchased two Hurco machines from Wycombe-based Hurco Europe Ltd to bring the work in-house. A Hurco VM10i vertical machining centre with a 4th-axis rotary table and tailstock arrangement plus a TM6i two-axis CNC lathe have been installed to perform a majority of the milling and turning operations required. They have greatly improved turnround speed and at the same time allow programs to be edited and prototypes to be remade quickly in response to surgeons' instructions.
Reliability and accuracyKevin Stamp, design director at OrthoSolutions, said: “We chose Hurco because it is a long-established business in the UK and their machines have a reputation for reliability and accuracy. The competitive price of the machines and the ease of programming made the choice an easy one. Furthermore the customer support is great. I have instant access to experienced engineers that can help me if I have any issues.”
Mr Stamp is particularly pleased with the way the screen graphics on Hurco’s WinMax control support the prototyping process. The ability to visualise the component, toolpath and tool simultaneously gives confidence that collisions will be avoided. He currently programs parts conversationally at the control, but to improve the cosmetic appearance of products even further, he intends to install a CAD/CAM system.
Although the machines have only been in operation for a short time, OrthoSolutions is already reaping the benefits. Mr Stamp gave the example of a steel prototype reamer, which would previously have taken 16 weeks for a sub-contractor to supply, that is now being machined in four days in-house.