Current Process:

The balls are formed one at a time from bar stock on a lathe in multiple roughing and finishing tool paths. Molded balls are purchased from a contract manufacturer, then turned to achieve the desired diameter and to remove mold imperfections such as parting lines.

Challenges:

Purchasing the balls can be expensive, and long lead times create a need for increased inventory levels and consumption of cash. Turning can be slow and inconsistent, resulting in long cycle times, high scrap rates, and surface finishes that generally require downstream grinding or honing to meet specifications.

Challenge

Manufacturers use lapping machines which are unable to hold consistent tolerances or capacity, creating inconsistent surface finishes and longer cycle times.

Provide a form grinding solution for 1" and 1.4" deodorant balls while meeting the customer's cycle time and surface finish requirements.

Challenge: To point and shape catheter bodies free of debris and scratches, at high production rates.

Challenge: To size implantable spinal cord stimulation devices that deliver precise doses of electricity to targeted nerve sites for patients suffering from chronic back problems. The device is long and flexible, which made it difficult to handle. It is also constructed of dissimilar materials of varying diameters, from metal conductive rings to fine electrical micro-wires to molded polymer and plastic supports, which made grinding a fine surface finish with stringent diameter control and without damage to the parts very challenging.

Challenge:  To size thin walled tubing used for surgical instruments insuring a mirror like 3Ra finish.

Challenge: To grind felt tips for pens. Customer required a high volume turnkey solution.