To most, the idea of working in a factory crafting components seems unattractive. Working in a “machine shop” can call to mind images of working in a dark factory all day, manufacturing part after part in a monotonous haze.
 
However, this couldn’t be farther from the truth when it comes to machining parts for the medical device industry. High-precision machining has significantly evolved from the lathes and mills of years past. Modern Swiss machines reach as high as 13-axis to make parts with complex geometries and can be programmed for optimal speeds and feeds. Hybrid manufacturing techniques are merging CNC machining with the additive laser sintering process. Multiple spindle machining is able to complete parts in a single setup, and some machines include capabilities like turning with live tooling and wire EDM. Laser machining continues to expand as well. Device manufacturers and their contract manufacturers rely on laser systems to make precise components with high levels of speed and accuracy, often at extremely low tolerances.
 
To gain more insight into the medical device machining industry, I spoke with Joshua Chaffee, sales engineer for ARCOR Laser Services, a Suffield, Conn.-based contract manufacturer that specializes in laser processing services, machining, and assembly. The breadth of his input was not included in the recent feature article entitled “Smooth Operator: Addressing Machining’s Talent Gap” (which can be read here), so his answers are included in the Q&A below.
 
Sam Brusco: What are the most exciting recent advances in machining technology? How is the technology evolving to meet the needs of medical device manufacturers?
Joshua Chaffee: One of the recent exciting advances in machining technology is the combination of laser cutting and welding in situ with traditional Swiss turning. We have been a leader in this technology for two to three years and have been fortunate to form a partnership at the machine OEM level. This technology is transforming the design options of medical device markets. In the case of laser cutting, flexible tubes, square geometry, single wall features, hypo tube cutting, etc. are all now very cost effective and compete with other technologies like EDM. Handshaking with this technology is the addition of laser welding. Now traditional Swiss-turn, laser cutting, and laser welding are combined into the same machine platform, producing functional parts from bar or tube stock. Combining this capability with automated load/unload and metrology makes for a very attractive technology.  
 
Brusco: Which services do you offer for medical device customers beyond machining? Why is it important to offer these services?
Chaffee: We offer a full suite of laser processing including cutting, welding, marking/etching, and drilling at both a macro and micro level. Assembly and post-processing are also under our umbrella. To remain competitive, it is important to be multi-dimensional and offer more than one technology or service. From a customer’s perspective, it’s advantageous to approve one supplier and issue one PO for a complete part.
 
Brusco: Which advances in laser processing technology have been most beneficial for manufacturing medical device parts, and why?
Chaffee: Advances in lasers have been and will continue to be rapid. Short and ultra-short pulse width lasers provide increased material flexibility, reduced thermal input, and very fine edge quality (in the case of laser cutting/drilling). Control of laser pulses has evolved in recent years. This allows for pulse shaping, improving processing of materials with lower melting temps, as well as achieving higher peak power with relatively inexpensive laser sources. Laser scan head technology has also improved including the ability to control X, Y, and Z axes in real time.
 
 
Brusco: Which types of medical device part manufacturing projects does your company find to be most challenging, and why?
Chaffee: In the case of contract manufacturing where the laser process is down-line from customer processes, or we are working with customer supplied material, it is imperative the communication and relationship are tight. Any unknown changes or variance in part quality or material can have a huge impact. We work hard to have customers’ processes handshake with ours.
 
Brusco: It has been said that the machining trade is struggling to attract new talented craftsmen. Have you found this to be true for your company? If so, why do you believe it is occurring and what steps does your company take to attract talent? If not, how have you been successful in attracting new talent?
Chaffee: Talent in the machining trade is challenging to hire. We find that talent is either in the waning years of their career, green, and/or comfortable with their current employer. All these situations have their advantages and disadvantages, so flexible strategies are required. We find mentoring recent graduates from tech schools or two-year programs works well. Our senior talent can then impart their knowledge base and best practices.
We have partnered with local community colleges who offer very comprehensive machining and laser-based curriculum. These partnerships have proven successful and give us access to students who want to perform.
 
Brusco: What will be expected of machinists in the coming years to ensure robust medical device part production?
Chaffee: Future machinists must be well-rounded and understand complementary processes. Hybrid technologies are becoming the norm and will continue to advance rapidly. To remain competitive, knowledge of these related processes will be a huge advantage. Knowledge of end use of the device is always a plus. This allows for open discussion of potential manufacturing roadblocks and/or process improvements. Cost drivers in the manufacturing process can also be discussed if the machinist understands fit, form, and function.
 
Brusco: Is there anything else you’d like to say regarding machining for medical device manufacturing, or are there any particularly important topics within the machining/laser processing sector that I have not asked about that you feel MPO readers should know?
Chaffee: OEMs should work with process experts and get them involved early in the design cycle. Waiting until late in the process or assuming design or materials are a given can lead to costly delays or redesign. Open dialogue with your key suppliers can reveal alternate designs or methods. We take this approach and look forward to taking on our customers’ challenges.