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 myriad of products that provides 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 3D printing a plastic model.
Next a steel prototype is manufactured, which in the past was subcontracted 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 a pair of Hurco machine tools to bring the work in-house.
A Hurco VM10i vertical machining centre with a 4th axis rotary table and tailstock arrangement plus a TM6i 2-axis CNC lathe have been installed to perform a majority of the milling and turning operations required.
They have greatly improved speed of turnaround and at the same time allow programs to be edited and prototypes to be remade quickly in response to surgeons' instructions.
Kevin Stamp, design director at OrthoSolutions, said: "We chose Hurco because they are 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 decision.
"Furthermore the customer support is great. I have instant access to experienced engineers that can help me if I have any issues.”
Kevin 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. Kevin gave the example of a steel prototype reamer, which would previously have taken 16 weeks for a subcontractor to supply, that is now being machined in four days in-house.
