30% more tool life, 8 hours unmanned, 21% more productivity, better quality
More efficient milling, longer unmanned production, less frequent changes: Together with Tungaloy-NTK Germany, the dental technology manufacturer Hager & Meisinger GmbH has strategically optimized the miniature processing of its implant components. The basis for this success was the structured 5-step program "RoadMAP to Success" from Tungaloy-NTK Germany – a proven roadmap for systematically reducing piece costs and sustainably increasing productivity. Through detailed process analysis and targeted tool selection along this "success plan," tool life could be increased by up to 30%, unmanned production times quadrupled, processing quality improved, and productivity increased by over twenty percent.
When it comes to micrometers, Meisinger does not joke – but knows a lot about precision. Since 1888, the company from Neuss has been manufacturing high-quality medical instruments and is considered one of the oldest and most efficient manufacturers of dental rotary instruments worldwide. With a clear focus on the requirements of dentists, implantologists, and laboratories, Meisinger has made a name for itself as an innovation leader over generations – both nationally and internationally. Especially in implantology, Meisinger sets standards: The product range extends from systems for implant bed preparation to micro-implant screws with just one millimeter in diameter.
Highest demands – zero tolerance
"Our products operate at the limits of what is possible. Therefore, it is all the more important that we can rely one hundred percent on every tool – otherwise, we cannot guarantee one hundred percent quality," summarizes Dennis Wörster, head of turning technology at Meisinger, the challenge. The processing of miniature components such as pull anchor screws and counterbore sleeves requires far more than just scaled-down machining processes. It is about absolute dimensional accuracy, mirror-smooth surfaces, and one hundred percent burr-free processing – because even the smallest deviations can impair function in the body. Complex geometries, tight tolerances, and the difficult machinability of titanium or stainless steel make production additionally demanding. These materials are biocompatible – but also hard, heat-sensitive, and unforgiving during processing.
"We work with safety-relevant components. Nothing can be left to chance," says Wörster. "Every step must be stable, repeatable, and economical – especially in unmanned production." A tool break or distortion not only means scrap but disrupts the entire process flow – down to traceability. Therefore, tools that not only cut reliably but also support the process are all the more important – day after day. "With Tungaloy-NTK Germany, we have a partner who understands exactly that. Together, we are optimizing not only tools but our entire manufacturing strategy."
Processes analyzed with micro precision
Before optimizations can take effect, a precise look at the existing situation is required. This is exactly where Tungaloy-NTK Germany's "RoadMAP to Success" comes into play: a defined 5-step plan that begins with a thorough analysis and leads to targeted cost reduction and efficiency improvement in clearly defined phases – from conception to validation to implementation. Each step is practical, measurable, and extensively tested – for sustainable success in machining.
In the first step, the entire manufacturing process was therefore analyzed together with the application technicians from Tungaloy-NTK Germany. All processing steps were systematically recorded. Machine run times, actual times, and tool usage were documented to make weaknesses and optimization opportunities visible.
"This thorough analysis laid the foundation for all further steps: It clearly showed where the optimization potentials lay. And it paved the way for the precise conception of a tool strategy, tailored to the components and requirements of Meisinger," says Dominik Uhl, product specialist for non-rotating tools at Tungaloy-NTK Germany.
Small tools, big impact
Instead of simply replacing existing tools, Meisinger, together with Tungaloy-NTK Germany, opted for a strategic optimization approach. Entire processing workflows were questioned, restructured, and all interfaces – from the machine through the clamping technology to the tool – carefully coordinated. A central component of the optimization was the complete processing of counterbore sleeves and pull anchor screws. "The goal was to cover as many processing steps as possible stably, precisely, and economically with optimally coordinated tool solutions. Today, high-precision indexable inserts and micro-tools are used, which have proven particularly effective with tight tolerances, complex geometries, and difficult-to-machine materials," explains Dominik Uhl.
When planning and over-turning the components, Meisinger uses the ModuMiniTurn and the TetraMiniCut. ModuMiniTurn, the modular holder system for long turning machines, allows for seconds-fast cutting head changes without removing the holder – while maintaining high repeat accuracy of under ±5 µm. In combination with TetraMiniCut, which offers the highest clamping rigidity and tool life thanks to its 3-point clamping system, a turning strategy is created that is not only efficient but also extremely process-safe and precise.
For the smallest holes, Meisinger relies on the GigaMiniDrill. The prepared cutting edge and optimized chip space geometry of the solid carbide micro-drills ensure safe self-centering and burr-free drilling – even with diameters starting from 0.1 mm.
The processing concept is complemented by TinyMiniTurn for internal turning and DuoJustCut, which ensures precise and repeatable parting processes with its stable clamping system. For milling the key surfaces on the counterbore sleeves, the modular TungMeister is additionally used – quick to change, reliable in processing.
Special solutions for specific applications
A central success factor was the close collaboration with the application technicians from Tungaloy. Together, tools were adapted to the specific requirements in titanium processing – for example, through specially developed cutting geometries and coatings that extend tool life and improve surface quality. Tungaloy-NTK Germany also provided consulting support in the design of clamping chucks and tool holders to achieve maximum stability and optimal vibration damping.
"We looked at the big picture – material, machine, tool, clamping technology. And that was the key to success," emphasizes Dennis Wörster. "Today, we have a system that not only delivers better results but also runs more efficiently and stably than ever before."
From numbers to arguments
Strategies are good – measurable results are better. The facts speak a clear language: tool life increased, processing times reduced, unmanned shifts extended – productivity improved across the board. Particularly impressive was the increase in unmanned production time: it was extended from two to now eight hours for one product. This means: a complete night shift now runs reliably without an operator. 'This extension is a real milestone for us,' says Wörster. 'It not only makes our production more efficient but also more predictable – and it noticeably lowers the unit costs.'
There was also a noticeable improvement in tool life: compared to the previously used solutions, Meisinger achieved an increase of up to 30 percent. This means not only fewer tool changes and reduced downtime but also a significantly more stable production – without the constant worry of unexpected failures. At the same time, the high performance of Tungaloy tools and the finely tuned cutting parameters ensured that processing times were noticeably shortened. The machines run smoother today, cycle times are shorter, and output per shift has significantly increased.
The economic side was also scrutinized. The result of the calculation speaks a clear language: the extended tool lives, reduced cycle times, and increased process reliability led to an overall productivity increase of around 21 percent. 'The numbers prove that our targeted tool optimization pays off not only qualitatively but also economically,' sums up Dominik Uhl.
Further optimization in sight
The success does not mark the end but rather the beginning of further developments. Currently, the focus is on optimizing the membrane fixation screw – a component with particularly delicate thread geometry, thin wall thicknesses, and tight fits. For this application, the MiniVLock system is used, which was specifically developed for precise thread turning on CNC lathes. Thanks to its unique insert clamping system with a V-shaped contact, it ensures maximum stability and process reliability. Initial tests have already shown: MiniVLock excels where precision, stability, and compactness are required in the smallest installation space.
The ShaperDuo is also currently being tested – it is intended to be used in the future for internal profiling of tension anchor screws. With the system, hexagonal, square, and Torx profiles can be produced reliably and accurately, without special equipment. Particularly with small diameters, the tool scores with its low cutting forces – ideal for delicate medical components. Initial tests on hex sizes between 1.0 and 1.4 millimeters show promising results: high fitting accuracy with noticeable cost savings.
A partnership with depth
The collaboration with Tungaloy-NTK Germany has proven to be a real gain for Meisinger – both technically and personally. From the first test to production, the technical consultants accompanied the process with great competence, close communication, and a clear hands-on mentality. Whether in tool selection, fine-tuning of cutting parameters, or solving complex machining issues – Meisinger could always rely on quick, informed support. Even in day-to-day business, Tungaloy-NTK Germany impresses with reliability, short response times, and high service quality.
'Tungaloy is not a classic supplier for us, but a true development partner,' emphasizes Dennis Wörster. 'We benefit not only from the high-performance tools but especially from the intensive support and know-how transfer that has sustainably advanced our production.' For Meisinger, it is clear: this partnership was not just a project but the beginning of continuous development – with Tungaloy-NTK Germany as a reliable partner by their side.
Contact:
