Engineering company Renishaw has collaborated with medical device manufacturer, Marle Group to help improve its powder flexibility for bespoke jobs and overall manufacturing accuracy.
As medical devices become more compact, intricate, and discreet, medical device manufacturers require technology that allows them to stay ahead of their market and produce high quality and accurate components.
Marle Group specialises in the production of large joints, such as knee and hip, with forging, casting, milling and polishing capabilities. It has recently grown the businesses by acquiring a separate 3D printing business, 3D Medlab who specialises in additive manufacturing in the medical sector.
Marle 3D Medlab was contacted by a customer to help integrate additive manufacturing (AM) into its facility, which opened the debate for better understanding about AM processes. As it had only just acquired 3D Medlab, additive manufacturing technology was new to Marle Group, so it needed technology experts to help guide them through the different technologies, applications and training that was required to make the new business venture successful.
Marle 3D Medlab specialises in manufacturing complex medical devices, that require technical expertise, accurate and rapid manufacturing capabilities. The specific size of a hip joint will change for each patient, so the components need to be highly accurate to comply with industry regulations and fit the patient’s body correctly. The short time frame between production and surgery also demands a rapid production process to deliver the parts on time.
Marle 3D Medlab contacted Renishaw in 2018 and after some consultation, it initially decided to install the RenAM 500 in its facility. Marle 3D Medlab installed two machines, one for research and development between itself and Renishaw and the second for the customer, so Marle 3D Medlab could train and develop processes on it before transferring it to the customer site.
After the successful integration and use of the two machines, Marle 3D Medlab invested in the RenAM 500Q Flex, with the first ever additive manufacturing with powder metallurgy (AMPM) module to support the future growth of its business.
The RenAM 500Q Flex is a four laser AM machine, which is a variant of the existing RenAM 500 range. The powder system enables manufacturers in R&D, pre-production or bureau environments to change between materials, without compromising on part quality or build capacity.
Chris Dimery, sales manager at Renishaw, said: “The unique flexibility of the RenAM 500Q Flex with the AMPM module allows 3D Medlab to use the laser in Pulsed and Continuous mode and easily swap between high value titanium grades, such as Ti6AI4V and Titanium-Tantal alloy. The added flexibility allows 3D Medlab to quickly adapt its batches to the specific requirements of its medical customers. It can fit multiple bespoke parts on one build plate, increasing productivity and accuracy, compared to casting and machining processes.”
Gael Volpi, head of additive manufacturing at Marle Group, added: “Marle 3D Medlab has been supported by Renishaw UK and Spain throughout the whole installation, training, and day-to-day running process. We have personal relationships with the process engineers and technical experts who are always at our disposal to help support us at any point. In the future, we will continue to focus on developing new products, processes, and validation techniques with AM processes as we expand into a new industry.”
