Computer numerical control (CNC) machining is a production method that leverages computer-controlled machines to accurately cut, shape, and form parts. It can fabricate complex geometries from materials like metal, plastic, or wood.

The term CNC machining encompasses several processes: Cutting, milling, turning, drilling, grinding, routing, and polishing. Because it follows pre-programmed instructions, CNC machines ensure high amounts of consistency, accuracy, and reliability. It’s also a cost-efficient manufacturing method because waste material, defects, manual work, and setup times are all minimized. Modern CNC machines tout advanced features like multi-axis capabilities, automated tool changers, and advanced automation to optimize the efficiency of production.

CNC machining’s versatility has fueled its adoption in every manufacturing sector, including aerospace, electronics, medical, and many others. Its precision, customization, and speed have revolutionized how medical devices and equipment are designed, manufactured, personalized, and used. 

Its level of accuracy is integral to produce surgical instruments, implants, and micro devices used in minimally invasive surgery—particularly important for surgeons who need precise and reliable instruments to perform delicate surgeries.

Although additive manufacturing receives most of the hype on this topic, CNC machining allows creation of personalized medical parts and devices that are tailored to a patient’s anatomy as well. Using patient-specific data like 3D scans or MRI images, the machines can precisely manufacture technologies that perfectly fit the patient’s body—for example, personalized orthopedic implants, dental prosthetics, and hearing aids. This can boost comfort, functionality, and treatment outcomes as well as speed patient recovery.

The method can also create complex geometries and intricate internal structures that other manufacturing methods may struggle to achieve. CNC machines can precisely carve out internal cavities, channels, and delicate features that are valuable when fabricating implants, micro devices, and surgical instruments. They’re also valuable for medical engineers and designers to create functional part and device models, letting them evaluate the design, fit, and function before production begins. This permits iterative design improvements and helps ensure devices are thoroughly tested and optimized before they’re released.

Further, integrating CNC machining with advanced technologies like automation and artificial intelligence (AI) has reduced errors and automated quality control processes, leading to more efficiency, lower production times, and better product quality. Automated CNC systems can operate continuously with minimal interaction from humans between operations, and some machines feature multi-axis machining and performing tasks on different surfaces of a part at the same time.

Manufacturers can also rapidly switch between producing one component and another by reprogramming machines. This cuts changeover time and allows different parts to be made on the same machine during a single shift, helping to speed production cycles, reduce downtime, and increase overall output.

CNC machining is also compatible with a number of materials, which includes metals, plastics, and composite materials. The versatility lets manufacturers choose the most suitable materials for specific medical applications, with considerations about biocompatibility, durability, and functionality. 

Even though industrial CNC machines can be expensive, they can provide significant cost savings in the long-term. They eliminate the need for dedicated jigs, fixtures, and specialized tooling for each part, helping minimize setup times, streamline production, and reduce manufacturing costs. Material optimization also helps reduce waste and cost, which is particularly crucial in the medical device sector—implants are often made using high-value materials like titanium and platinum. 

The technique is used to fabricate numerous medical parts and components. Some of them include surgical tools, implants, prosthetics and orthotics, micro devices, medical device enclosures and housings, diagnostic equipment, instruments for minimally invasive surgery, and rehabilitation and assistive devices.

The future of CNC machining in the medical sector is quite promising—advancements in automation, materials, integration with additive manufacturing, digital technologies, customization, and quality assurance continue to drive innovation and lead to development of safer, more efficient, and patient-centric medical devices.

In order to gain further insights into machining and laser processing for medical device manufacturing, Medical Product Outsourcing spoke to half a dozen experts in the industry over the past few weeks:

•  David Bosom, CEO, Lasentum
• Jerome Clavel, Head of Academy, United Machining
• Chris Huntington, CEO, PrecisionX Group
• Shawn Murphy, Director of Engineering, Vantedge Medical
• Erik Poulsen, Medical Segment Manager, United Machining
• Rolf Schaenzel, Director of Applications, United Machining

Sam Brusco: What latest technological or operational advances have most impacted your machining/laser processing capabilities for medical device manufacturing?

David Bosom: Our systems deliver precision laser processes such as welding, marking, and cutting, with a strong focus on plastic welding. In medical device manufacturing, traditional joining methods can lead to particle generation or introduce thermal and mechanical stress that compromise sensitive components. Using the right laser technology, we can avoid these issues and help medical device manufacturers meet the sector’s strict requirements.

Our systems provide precise control of energy and pressure, ensuring clean, stable, and repeatable welds. This makes it possible to achieve the highest standards of quality and compliance while guaranteeing consistency in life-saving device production.

One of the most significant innovations in our systems is the Advanced Thermal Analysis. By capturing and processing thermal imaging data of the welding, we can assess weld quality with greater precision and provide full traceability of each process. This not only improves reliability but also gives manufacturers stronger assurance of compliance with medical device standards.

Chris Huntington: We are leveraging artificial intelligence (AI) to optimize and plan machining paths to deliver precision with best-in-class efficiency. The self-learning AI we utilize grows with historical data to enhance our approach for machining new geometries, boosting efficiency and significantly reducing lead times. By incorporating AI, we have effectively established a continuous improvement cycle that enhances performance while limiting labor hours and improving performance.

Shawn Murphy: Implementing automation technologies across machining, laser, and assembly applications has made the greatest impact across our organization.

This includes workpiece tending systems that support higher volumes by enabling a single operator to manage multiple CNC machines. It also includes automated cells that perform several post-machining operations such as laser welding, deburring, light secondary machining on welded assemblies, and dimensional inspection. Closed-loop machining uses skip-signal measurement probes for in-machine inspection and real-time tool path correction.

Inspection results are displayed on each machine’s HMI, providing dimensional data for each iteration along with live trend analysis. These in-process inspection reports are automatically archived, giving us a detailed historical record for traceability and continuous process refinement. The success of these implementations continues to drive us toward broader adoption of automation techniques across our organization.

Erik Poulsen: The arrival of the LASER S 500 (U) has proven to be a game-changer for medical device manufacturing. This machine was completely redesigned to optimize speed and precision. It uses water-cooled linear and torque motors on most drives, glass scales, new software, and a digital Z-axis on the laser that allows us to move blindingly fast. 

Processing times to laser structure products—essentially “blasting” the surface with an effect similar to grit blasting—have decreased significantly. Devices like shoulder or hip implants can be structured in just a few minutes. We can now replace masking and grit blasting with a clean, digital process that can be fully automated. It’s generating a lot of interest for us!

Brusco: What steps do you take to ensure machine operators are properly trained and kept up to date on new manufacturing technologies?

Jerome Clavel & Rolf Schaenzel: This is such a great topic. Training is a vital part of any successful manufacturing operation, especially as customers choose our machines to gain a competitive edge and push the boundaries of what’s possible. Recognizing this, we place a strong emphasis on operator education. The U.S. uses both the global Academy and our own internal team to support customer training. 

In fact, a very big part of our team’s efforts is dedicated to training. In 2024, we had over 200 training programs. There are standard training modules that exist which cover every technology we offer, from milling to EDM to laser—and even tooling and automation. Modules start from the basics of working with and maintaining the machine, up to some of the finer points of CNC programming, cutting strategies, and process optimization. We can train technicians at our facility or at the customer site. Trainings are very often tailored to suit a customer’s specific needs and objectives.

Huntington: To ensure machine operators remain proficient and updated with evolving technologies, we proactively integrate learnings from industry-leading technology exhibitions. Our operators receive regular trainings focused on the latest machining techniques and industry best practices, empowering them to effectively apply advanced skills to their daily tasks. The ongoing professional development ensures our workforce remains aligned with cutting edge technological advancements, while also providing them a pathway to professional advancement.

Murphy: Operator training is tailored to the complexity, volume, and technology associated with each product line. With a focus on precision-machined metal components for medtech, we take a structured yet flexible approach to developing operator capability.

High-volume components used in surgical stapling are produced on dedicated, lights-out equipment, where operators are trained to monitor and manage automation systems efficiently. Low-volume, large-format assemblies—such as those used in radiation therapy—require a higher degree of hands-on skill. Operators are trained in both robotic and manual welding techniques, followed by final machining. Medium-volume systems for robotic-assisted surgery often involve palletized machining centers, requiring operators to interface with integrated workpiece management technologies.

For complex, manual processes, we emphasize a traditional mentor–apprentice model. In these cases, operators progress through hands-on training, often supported by formal state-recognized apprenticeship programs. For more automated applications, training focuses on interfacing with HMI and computer systems to interpret real-time operational data and instructions.

We promote a servant leadership model where knowledge sharing and process transparency are essential. Whether it’s one-on-one training or group workshops, our goal is to equip operators with the tools, understanding, and support needed to succeed in a rapidly evolving manufacturing environment.

Brusco: Do you employ Industry 4.0 technologies in your manufacturing process? If so, which ones and how do they ensure manufacturing excellence?

Bosom: Rather than only using Industry 4.0 technologies to build our systems, we integrate them into the systems themselves. Our laser systems capture full process data with part traceability, connect to factory networks via Ethernet/IP, OPC/UA and MES, and adapt from stand-alone workstations to automated lines through modular design and RFID technology.

Huntington: Our manufacturing processes incorporate Industry 4.0 technologies, including AI-driven machining optimization, automated ultrasonic cleaning systems featuring intelligent monitoring capabilities, and advanced optical defect detection embedded within our tools. These technologies enhance product quality, minimize scrap rates, increase throughput, and provide real time monitoring and feedback, driving continuous improvement and manufacturing excellence.

Murphy: We actively implement Industry 4.0 technologies to improve process control, equipment health, and overall manufacturing performance across our platform.

Real-time monitoring and predictive maintenance: Modern CNC controllers provide historical data on spindle and axis loads, while additional sensors measure vibration. These data streams feed into our predictive maintenance program, enabling early detection of wear conditions that could affect product quality or lead to unplanned downtime.

Adaptive manufacturing for tool monitoring: Tool load monitoring systems flag cutting tools that operate outside of optimal ranges. In some applications, the system dynamically adjusts cutting parameters to prevent tool failure. This is especially valuable when machining large-format parts, where a single broken tool could result in thousands of dollars in lost time and material.

Digital twins and simulation: Verification software simulates CNC programs generated from our CAM systems, allowing us to detect potential issues—such as collisions or toolpath errors—before a single part is cut. This reduces scrap risk and protects high-value machine assets.

Automation and robotics: We maintain in-house automation integration capabilities, including workpiece tending, in-line inspection, unmanned machining, and automated assembly. A centralized automation team supports all sites, enabling scalable solutions from full system integrations to cost-effective enhancements of existing operations.

Together, these technologies strengthen our commitment to manufacturing excellence by ensuring process consistency, reducing risk, and enabling smarter, data-driven decisions.

Poulsen: We do—in fact, I think our organization is ahead of the curve on this topic. Each and every machine that we produce includes the hardware and software to allow remote connection with our “My rConnect” system. This technology enables real-time monitoring of the machine’s status and allows customers to securely connect with our service team through an encrypted pathway, granting them remote access to the machine when needed. 

More than that, we allow key manufacturing data for a specific product to be stored and analyzed, providing a type of “digital twin” of the process. This can be an incredibly valuable tool when manufacturing critical components that are difficult to inspect through traditional means. 

There is so much to say about Industry 4.0 and the opportunities it creates for improving production. For now, I’ll simply say our digital capabilities are significant, based on international standards such as umati and OPC UA, and are designed to scale alongside the customer as they expand their own digital infrastructure. 

Brusco: Anything else you’d like to say regarding machining services and equipment for medical device manufacturing?

Bosom: Laser processes have proven to be highly effective in medical device manufacturing, not only for demanding applications, but also for high volume production. Its ability to deliver stable, repeatable processes with full traceability makes it a reliable solution where both performance and compliance are critical.

We believe laser plastic welding is not just about joining parts, but about delivering the stability, traceability, and confidence that medical device manufacturing demands.

Huntington: We differentiate ourself by integrating multiple niche manufacturing methods under one roof, allowing seamless execution of complex projects. We specialize in challenging materials, excelling in processing difficult-to-machine metals such as nitinol, high-grade titanium, cobalt-chrome, and other high-performance alloys. Additionally, our automated cleaning system for Class III components significantly improves throughput while ensuring uptime through an advanced predictive maintenance program.

Murphy: We are a metals-focused contract manufacturer supporting OEMs and their extended supply chains across the medtech industry. With deep expertise in CNC machining—from small to large-format components—and comprehensive post-processing capabilities, we combine advanced technology with top-tier talent across all roles.

Our recent investments in dedicated equipment for rapid prototyping enable us to support customers from the earliest stages of product development. These same teams bring speed, precision, and attention to detail throughout production, allowing us to operate with the agility of a smaller manufacturer while delivering the scalability of a larger platform.

We are proud to serve as a responsive, reliable, and forward-thinking partner—committed to quality, innovation, and helping our customers bring life-changing medical technologies to market faster and more effectively.

Poulsen: Major trends in the medical industry—such as the growth in robotic and minimally invasive surgery—are driving an increase in precision for the components that make up these devices. More and more work orders include parts with tolerances of just a few microns (below ± 0.0002 inches), which is a real challenge for shops that need to run 12 to 24 hours a day. 

Some manufacturers face unacceptably high scrap rates or rely on machines that, while capable, require a technician with “golden fingers” to manage the setup and keep it operating within tolerance. Consistently producing high-precision components demands a machine purpose-built for accuracy. Engineering and building such machines are at the heart of our organization’s DNA.