In micro-surgery, the quality of micro-surgical instruments plays a significant role in the success of an operation. This places the highest demands on their manufacturing in terms of precision, durability, and processing. MICROMA Martin Alber GmbH & Co. KG from Irndorf has been a specialist in the production of micro-surgical instruments for many years. With a tailored milling tool from NACHREINER GmbH from Balingen-Weilstetten, the medical technology experts were able to significantly reduce processing time – and that with almost double tool life. A crucial detail in adapting the milling cutter was the powerful HiPIMS coating.
Surgical spring scissors, needle holders, and tweezers in the smallest dimensions are the specialty of MICROMA. To meet the extreme demands for such high-precision micro-surgical instruments, the highest quality standards are mandatory. The success factor at MICROMA is the combination of specially designed special machines, high-quality materials, and powerful precision tools. 'Precision and quality are indispensable in medical technology and are uncompromisingly maintained in our production. But of course, cost-effectiveness and productivity are always our focus. That’s why we regularly put our processes to the test to uncover optimization potentials. We were looking for an efficient milling tool to reduce our processing times. We found it at NACHREINER,' says Jan Alber, Production Manager at MICROMA.
In-house coating expertise for even more differentiated solutions
Precision tools for demanding machining tasks of metal, non-ferrous metals, plastics, and composite materials are the expertise of NACHREINER. The company produces as much as possible in-house with optimized manufacturing, quality, and service processes. The tempered production, modern technology for edge preparation and optimization of microgeometry, as well as innovative grinding, measuring, and automation technology are fixed components in their tool production. For several years now, an in-house coating line from CemeCon around the CC800 HiPIMS coating system has been a central part of production.
Martin Seifriz, Managing Director of NACHREINER GmbH: 'We aim to develop the best cutting tools for our customers now and in the future, so they can achieve excellent quality in their products. Thanks to our high depth of manufacturing, including premium coating expertise, we can deliver outstanding solutions here. The CC800 HiPIMS is the key to differentiate ourselves even better from the competition with high-quality coating solutions.'
With HiPIMS technology, CemeCon has significantly increased the quality and performance of coatings compared to other processes. The technology is flexible and suitable for coating many different tool variants. Whether small batches or large quantities with high piece numbers: it can be optimally adapted to different requirements, from micro-tools to tools for heavy machining – and this within the shortest time. Across this entire range, HiPIMS coatings have excellent properties: they are smooth, adhesive, hard, and at the same time tough, have a fine crystalline, dense morphology, tailored intrinsic stresses, and high thermal stability. The uniform layer thickness distribution also contributes to optimal wear protection of the cutting tools. The perfect combination for precision tools in premium quality.
Application with special challenges
The production of micro-surgical instruments places high demands on the cutting tools: they are made from stainless steel (1.4034 or 1.4022). These high-quality steels are characterized by high corrosion and acid resistance. They are also very tough and have low thermal conductivity.
Excellent properties for use in medical technology, but a challenging combination for machining. Because when drilling, milling, or turning, high temperatures occur at the cutting edge that can damage the tool. Furthermore, the machining itself is very demanding: the milling tool must achieve a high material removal rate on a long and thin component while also achieving good surface qualities.
Precise coordination for excellent performance
In the first step, MICROMA switched to the solid carbide HPC Superstar milling cutter from the NACHREINER standard program, which was then further adapted to the specific application in a second step. 'The combination of a 3-flute and a 6-flute tool in our Superstar milling cutter allows for both efficient roughing and smooth finishing with excellent surface quality. The unequal division prevents vibrations and oscillations, contributing to very good running smoothness and reduced friction,' explains Martin Seifriz.
Even with the standard variant, MICROMA was able to triple the feed rate and increase the cutting speed by more than 30 percent. 'That was already a great success! We shortened our processing time and achieved first-class processing results with increased productivity,' says Jan Alber. But that was just the beginning; optimizing the tool further improved the results. The experts closely coordinated the milling cutter specifically for MICROMA's application and nearly doubled the tool life. In addition to the targeted adjustment of the microgeometry, the coordinated TiAlSiN coating provided the additional performance boost.
The standard milling cutter from NACHREINER has an AITiN coating. However, for machining stainless steel, the TiAlSiN coating offers significant advantages: it optimally protects the tool from heat in the machining process thanks to its high thermal stability up to 1,100°C, and the heat is dissipated through the chip. 'The extreme smoothness due to the HiPIMS process further reduces the heat. In addition, TiAlSiN has a low affinity for stainless steels. This reliably prevents built-up edges and ensures process security,' explains Marc Semder, Sales Manager at CemeCon, the advantages of the coordinated coating solution.
Successful partnership
The collaboration between MICROMA and NACHREINER shows how crucial intensive communication between the user and tool manufacturer is. Through the use of CemeCon's HiPIMS technology and the targeted optimization of tool geometry, MICROMA was able to reduce processing time while significantly increasing tool life. A result that excites everyone!
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