In the world of modern manufacturing, there is, statistically speaking, no room for error. This is especially true in medical device production, where lives can depend on the accuracy of your output. At MedFab Precision Solutions, we should know–we have literally built our name on it.

Today’s manufacturing customers expect consistent precision 100% of the time. If this sounds unreasonable, it isn’t. The technology available through modern CNC machining, together with advancements in engineering, materials science, and process control, give capable operators the potential to produce near-perfect parts with every run.

Consistent Results with Close Tolerances

For MedFab, extreme precision in CNC machining is not an objective, but an imperative. To consistently achieve tolerances as tight as ±0.0002 inches, we have developed a distinctive approach to our work that relies on advanced engineering, rigorous process control, and an ongoing quest for continuous improvement, as promised by our QMS ISO 13485 certification. Meanwhile, our production process is structured around three critical areas of focus:

Fixture Design

The underpinning of any precision CNC milling operation is the stable positioning of the workpiece. MedFab engineers are experts in fixture design. Our application-specific fixtures eliminate micro-movement, reduce clamping deformation, and guarantee part conformity.

MedFab fixtures utilize rigid, thermally stable materials and stress-relieved components to minimize the effects of machine vibration and heat growth on part positioning. Precision locating features such as hardened datums, custom nests, and vacuum-assisted plates ensure the workpiece is positioned precisely where the cutting tool expects to find it. 

This focus on fixturing is crucial for medical device manufacturing, with its intricate geometries, thin wall sections, and close tolerances. MedFab fixtures keep stack-up errors down while shortening inspection times. They also help deliver high yields on the first pass.

Tool-Path Optimization

Once the workpiece is securely fixed, MedFab maximizes accuracy and efficiency through sophisticated tool-path planning. Complex geometries, micro-features, and tight tolerance requirements can’t be guaranteed through generic CAM strategies. Our programmers apply dynamic tool paths, constant engagement milling, and smooth arc-transition moves to minimize tool deflection and apply consistent cutting force.

On our high-precision CNC machine tools, our operators can machine multiple surfaces in a single setup, eliminating the need for repeated repositionings, which is where dimensional errors are most likely to occur. MedFab also applies real-time machine feedback for spindle-load monitoring and adaptive feed control, assuring surface integrity and geometric accuracy.

Finally, while optimized tool paths are championed primarily for improving quality, precision, and repeatability of output, they can also extend tool life, reduce cycle times, and minimize waste. 

Thru-Tool Coolant Strategies

One of the most important factors to consider when working in high-precision CNC machining is thermal stability. Heat generated by machining can cause distortion in the tool, the workpiece, or both. Coolant must be applied during the operation to keep this from occurring. Deciding what kind of coolant to use for each operation and how and when it should be applied are at the heart of what has become a specialty unto itself–coolant strategizing. 

MedFab applies tightly controlled coolant strategies devised specifically for each operation based on materials used. For materials like stainless steel, titanium, and difficult-to-machine, superhard alloys, temperature-regulated, high-pressure, high-flow and thru-tool coolant can prevent thermal distortion in both the tool and workpiece. 

MedFab–Measure the Difference 

When the distance between success and failure can be measured in microns, you need every advantage in your favor. It isn’t luck. It isn’t fate. Consistent success in high-precision machining can only be guaranteed through complex engineering by experts in specialized tooling and machining strategies, with the added assurances of continuous validation and real-time machine data. 

These are the best practices MedFab Precision Solutions follows to ensure our customers take delivery of parts they can rely on every time. The challenge may seem complex, but for you, the solution is simple: get in touch with MedFab.