Changes Give a New Shape to Machining

If you look in the dictionary, you'll find that the definition of machining -"to cut, shape, or finish by machine"- hasn't changed. But that can't be said for much else about the subject. In recent years, machining materials, equipment, processes, and related services have all changed in important ways.

The changes were made to satisfy the constant demand for better and smaller products, faster turnaround times, and more contract services. In addition, machining firms have been forced to change in order to keep up with tough competitors both in the United States and abroad. Taken together, the changes are a boon for medical device firms that want more for their machining dollar.

A Role For Ceramics
New plastic formulations can also replace metals in many medical devices. Mike Kartsonis, president of Dynamic Fabrication Inc. (Santa Ana, CA), a contract machining firm, says plastics are "getting stronger and lasting longer." Compared with metal, plastics "cut like butter," he says. "When you're cutting a hole in plastic, you can have the drill going three times as fast as it goes when you're drilling stainless [steel]." In addition, he says, plastics are less expensive than metals and may last as long.

Machine Evolution
Whatever the material, new equipment can machine it into parts faster than ever. "Five years ago, it might have taken 30 seconds to drill a hole in a piece of titanium," Kartsonis says. "Now, with high-speed spindles, it takes half that time."

A finished part measuring 0.3 x O.5 x O.5 in., with three 0.013- in.-diam holes and two 0.030-in.-diam holes.

A Changing Industry
The question was asked about the now common practice of companies shipping their precision machining to Mexico and China, to take advantage of the cheaper source of labor. It was also stated that perhaps the more complex, high-end parts will stay here.

But for how long? Foreign operations "don't have high-end tooling and automation technology yet," Kartsonis says, "but they're gaining all the time." In fact, he adds, U.S. firms are transferring machining expertise to plants they're operating in other countries.

Proximity to a contractor can also reduce turnaround time. If customers need something quickly, Kartsonis says, "we can get it done because we're right in their backyard."

Conclusion
In recent years, change has come to virtually every aspect of machining. Materials, equipment, and processes have improved to satisfy demanding medical device firms. In addition, contract manufacturing companies are offering new services and special deals in an effort to survive in an intensely competitive industry. As a result, their customers are getting more for less, and getting it faster than ever before. Says Kartsonis, "That's what everybody expects now."