Medical Solutions from Kyocera SGS by kyocera-sgstool

MEDICAL SOLUTIONS

Create a better way

Contents............................................................................. 3

Hip Stem Solutions........................................................... 31

About Us............................................................................. 5

Acetabular Cup Components........................................... 33

Our Purpose, Vision & Values............................................. 7

Acetabular Cup Solutions................................................. 35

The Challenges We Face..................................................... 9

Trauma and Spinal Components....................................... 37

End Mill Matrix................................................................. 11

Trauma and Spinal Solutions............................................ 39

Replacement Knee Components...................................... 13

Dental Implant Components............................................ 43

Femoral Knee Components.............................................. 15

Dental Implant Solutions.................................................. 45

Femoral Knee Solutions.................................................... 17

SGS Special Medical Solutions.......................................... 49

Bearing Insert Components.............................................. 19

Hardcoating Technologies................................................ 51

Bearing Insert Solutions................................................... 21

Catalogues and Brochures................................................ 53

Tibial Tray Components.................................................... 23

Technical Services............................................................. 55

Tibial Tray Solutions.......................................................... 25

Regrind, Recoat and Alteration Services.......................... 57

Replacement Hip Components......................................... 27

SGS Tool Wizard................................................................ 59

Contents

CONTENTS

Hip Stem Components...................................................... 29

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

KYOCERA SGS Precision Tools (KSPT) is a global ISO-certified manufacturer of industry-leading solid carbide cutting tools. KSPT is proud to have pioneered some of the worldâ&#x20AC;&#x2122;s most advanced cutting tool technologies, resulting from rigorous product, coating and material testing within its Global Innovation Centre. We have manufacturing sites in the United States and United Kingdom and the KSPT European Headquarters are in Wokingham, Berkshire, UK.

Our European office specialises in bespoke and modified tooling, which means we find design tooling solutions to optimise your manufacturing performance.

We offer our clients unique solutions and support, helping solve difficult project challenges in their markets.

About Us

WHO WE ARE

In 2016, Kyocera merged with SGS Precision Tools. The merger has ultimately been a huge success between two companies sharing the same focus on client service.

AWARD WINNING In 2019, KSPTE were voted Best High-Performance Tooling Manufacturer in the SME News Enterprise Awards. We were also finalists for the Thames Valley Chamber of Commerce Business Awards for Workplace Wellbeing.

Our global network of sales representatives and industrial distributors sell into more than 60 countries and can therefore offer you a networked resource capable of solving your most difficult Medical machining challenges.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

OUR CUSTOMER CARE

We will be the global centre of Excellence for solid cutting tool solutions whilst enriching the lives of our people and partners.

We offer our clients unique solutions and support, helping them to solve difficult project challenges in their markets.

Our commitment is to our customers and to our employees. Investing in both enables us to grow and innovate together with our customers, resulting in success all-round. Our values exist to channel us ever further towards achieving our mission.

L E A D BY E X A M P L E

Our sales engineers and technical team explore our customersâ&#x20AC;&#x2122; goals and work with them to reduce set-up times and machining cycle times, improve quality and process reliability through the design and manufacture of specialised tools. We are a solutions provider rather than just providing high-quality tools.

It is this that sets us apart from our competitors. We do more than just produce tools; we employ a highly skilled technical sales team, who often think of completely different ways of giving the customer what they need rather than just using off-the-shelf products. They even go as far as developing new concepts and geometries to ensure we meet our customers needs.

BE THE BEST WE CAN BE

FA M I LY S P I R I T

B R I N G I D E A S, E N E R GY A N D F U N

Our Purpose, Vision & Values

OUR PURPOSE, VISION & VALUES

CHALLENGE AND BE CHALLENGED

WHAT YOU CAN EXPECT FROM US

An express service for urgent orders

Product research and development

Product engineering and tool application support

CAD/CAM software support

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Multilingual sales and technical support

Same-day despatch on stock items

On-site customer training

Annual Customer Satisfaction Survey

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

The Medical sector continues to grow as new biocompatible materials are found and the life expectancy of people in the developed world extends further. In addition, health issues such as disease, trauma, arthritis and obesity are also helping to the drive demand for Medical implants. With this ever-increasing demand, and the challenges presented by new materials, comes a drive for more efficient, stable and cost-effective manufacturing processes. The drive to reduce costs has never been more in focus following recent worldwide economic issues such as the Coronavirus crisis.

The Challenges We Face

MEDICAL MANUFACTURING THE CHALLENGES WE FACE difficult materials such as titanium, cobalt chrome, and stainless steel materials often used in medical devices because of their non-reactivity with the body. Issues with the removal of coolant used in manufacturing have also led to new solutions for cooling the machining process such as C02 gas. Working closely with medical manufacturers we have developed many new and innovative milling and drilling solutions designed specifically to overcome the challenges faced by the Medical market.

The CNC machining of surgical implants presents many challenges. These include small-scale machining or micromachining, because implanted devices often consist of very tiny components, and machining

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Name

Series

Type

page No.

Barrel Tools

Special

Mill

Taper Ball Nose Tools

Special

Mill

Ski-Carb

Mill

Condyle Form Tool

Special

Mill

H-Carb

Mill

High-Feed

Special

Mill

Z-Carb HPR

Mill

Combi-Drill

Special

Drill

Series 33

Mill

Combi-Tool

Special

Mill / Drill

V-Carb

Mill

Hi-PerCarb

135

Drill

Z-Carb-AP

Z1P

Mill

Micro-Tool

Mill

Main Key Primary Function

• •

• • • • • • • • • •

• •

• • • • • • • • • •

• •

• • • • • • • • • •

# Flutes

Flute Index

Rake ˚

Coating

4, 6 & 8

≠

Ti-Namite-M Ti-Namite-X

4&5

≠

Ti-Namite-M Ti-Namite-X

+++

Ti-Namite-B

≠

+++

Un-Coated

≠

Ti-Namite-M Ti-Namite-X

2, 3, 4 &6

≠

Ti-Namite-X

≠

Ti-Namite-M Ti-Namite-A

Ti-Namite-M Ti-Namite-X

≠

Ti-Namite-A

2+4

Ti-Namite-M Ti-Namite-X

≠

Ti-Namite-A

≠

Ti-Namite-X

≠

Ti-Namite-X

2&4

≠

Ti-Namite-X

Material Key

•

Secondary Function Coolant Required

material

•

Stainless Steel

17-4 PH forged / cast & 316

Titanium Alloys

Titanium

Plastics, Composites

Polyethylene

Cobalt Chrome

CoCrMo / CoNiCrMo

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

• • •

Finishing

• • • •

• • •

•

HSM

• • • •

HFM

•

Profiling

Slotting

• • • • •

•

• •

•

• •

•

Drilling

End Mill Matrix

END MILL MATRIX

• • •

Coating Key Ti-Namite-A = AlTiN Ti-Namite-X = AlTiN-based nanostructured Ti-Namite-M = AlTiSiN nanocomposite Ti-Namite-B = TiB2

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

TOTAL KNEE IMPLANT

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Replacement Knee Components

REPLACEMENT KNEE COMPONENTS

FEMORAL KNEE SOLUTIONS

Femoral knee replacement parts mimic the natural shape of the joint and are usually made from cobalt chrome and 17-4 PH stainless steel.

SGS has a comprehensive range of offthe-shelf high-performance tooling with geometries well suited to the machining of cobalt chrome and 17-4 PH stainless steel.

Due to the tight tolerances and surface finishes required, femoral parts are usually machined on 5-axis grinding machines. However, this process can generate high temperatures that may distort the metalÂ and lead to scrapped parts.

The challenge when milling is to achieve a burr-free profile with superior surface finish that minimises the need for linishing and manual polishing, and at the same time maximises productivity and tool life.

In addition, we have developed specific tooling solutions for various areas of femoral components, including taper ball end cutters for box and cam sections, and barrel cutters for the main condyle surfaces.

The drive for more efficient, stable and cost-effective manufacturing processes has in recent years seen medical manufacturers start to move towards milling solutions.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Femoral Knee Components

FEMORAL KNEE COMPONENTS

SGS FEMORAL KNEE SOLUTIONS

Milling Condyle surfaces – Barrel tools

Milling box section feature – Taper ball nose tools

The condyle surfaces represent the largest portion of cycle time when machining femoral components. These surfaces have traditionally been milled with ball nose cutters using a scanning strategy.

The box section feature of femoral components present challenges when milling due to deep walls, small corners and high surface finish requirements that minimise manual polishing.

Whilst this strategy delivers the required surface finish, the small step overs result in an unsatisfactory cycle time. The SGS range of barrel tools have achieved step overs of up to 3.0mm and a feed rate of over 800mm/min whilst still delivering surface finishes within tolerance.

SGS’s tapered ball end tool solutions benefit from our patented vibration-reducing geometries that deliver the required component surface finishes, whilst our choice of carbide and coatings help to maximise tool life.

Condyle surface machining Application Details Operation

Solution Advantages

Cutting Data - Ø12mm / R200mm

Finishing condyle surface

Speed

Cycle time reduction & dimensional accuracy

Feed

Tool

SGS Barrel Tool Ø12mm / R200mm

Radial (ae)

2.0 mm

Material

Cobalt chrome

Depth (ap)

0.5 mm

Coolant

Emulsion - Flood

Tool life

60 parts

Requirement

40-50 m/min

800 mm/min

9 Reduction in the amount of scrap

Box section feature machining

9 Reduction in post milling linishing

Result: Cycle time reduction of 40% and dimensional accuracy improvement

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Solution Advantages 9 Improved surface finishes

Application Details

Cutting Data - Ø8mm

Operation

Finishing box section feature

Speed

Requirement

Surface finish and dimensional accuracy

Feed

572 mm/min

Tool

SGS Taper Ball Nose Tool - Ø8mm

Radial (ae)

0.3 mm

Material

Cobalt chrome

Depth (ap)

22.0 mm

Coolant

Emulsion - Flood

Tool life

1 hour 30 mins

9 Long tool life (3h recorded) 9 Stable process

Femoral Knee Solutions

SGS FEMORAL KNEE SOLUTIONS

40-50 m/min

9 Stable, accurate process 9 Lower cost per part 9 Reduction in post milling polishing

Result: Surface finish and dimensional accuracy improvement

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

BEARING INSERT SOLUTIONS

The bearing insert is made from polyethylene and is fitted between the femoral and tibial components to avoid metal-on-metal contact.

SGS have developed specific ultra-sharp tooling geometries, such as those seen on our high-performance Ski-Carb range, that overcome these issues.

The componentâ&#x20AC;&#x2122;s complex design, tight tolerances and stringyÂ material properties can create machining challenges

Ski-Carb geometries are often applied to our special tooling solutions such as t-slot and form cutters that enable the complex shapes of bearing inserts to be more easily manufactured.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Bearing Insert Components

BEARING INSERT COMPONENTS

SGS BEARING INSERT SOLUTIONS

Milling of Polyethylene - Ski-Carb

Milling Condyle surface – Form tools

General machining of polyethylene medical components can be difficult due to the stringy nature of the material.

Form tools can also be produced with the Ski-Carb geometry to the exacting tolerances demanded by this type of component. The solution shown is for machining the condyle surface of the bearing insert that the upper convex-shaped femoral component is located in. Quality of the cutting edge is key.

SGS’s Ski-Carb solution has a high helix angle of 45°, whilst the ski-land with primary and secondary flute wall construction minimises chip interference by directing chips away from the secondary flute. This combination of geometry helps to eliminate burrs and produce satisfactory surface finishes.

Profile machining

Solution Advantages

Condyle surface machining

Solution Advantages

9 Improved component quality

Application Details

Cutting Data - Ø8mm

Operation

Profiling outer diameter

Speed

Requirement

Cycle time reduction and surface finish

Feed

Tool

Ski-Carb tool Ø8mm

Material Coolant

9 Dimensional accuracy

Application Details

Cutting Data - Ø25mm

9 Stable, accurate process

Operation

Finishing condyle surface

Speed

300 m/min

9 Elimination of post milling de-burring

4500 mm/min

Requirement

Surface finish and dimensional accuracy

Feed

2500 mm/min

Radial (ae)

1.0 mm

Tool

Special form tool Ø25mm / R35mm

Radial (ae)

38 mm

Polyethylene

Depth (ap)

6.0 mm

Material

Polyethylene

Depth (ap)

0.5 mm

Air-Dry

Tool life

3 hours

Coolant

Air-Dry

Tool life

3 hours

375 m/min

9 Improved productivity 9 Maximised profitability 9 Lower process costs

Result: Cycle time reduction of 37% and elimination of burrs

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Bearing Insert Solutions

SGS BEARING INSERT SOLUTIONS

9 Tool regrind available to reduce costs

Result: Surface finish improvement and cycle time reduction of 25%

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

TIBIAL TRAY SOLUTIONS

The final element of a total knee replacement is the tibial tray, which supports the upper part of the implant. Typically, tibial trays are made from titanium and cobalt chrome.

SGS has a comprehensive range of off-theshelf high-performance tooling with features such as variable pitch, helix, and rake and edge preparations, making them ideal for machining difficult materials such as titanium and cobalt chrome.

Like all medical components, the tibial tray presents challenges in terms of surface finish and productivity requirements.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

SGS have developed new high-feed geometries that significantly reduce cycle times whilst at the same time minimising burrs.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Tibial Tray Components

TIBIAL TRAY COMPONENTS

SGS TIBIAL TRAY SOLUTIONS

Milling of titanium and cobalt chrome

High feed milling solution

SGS were the first cutting tool manufacturer to launch variable geometry tooling on to the market. Our high-performance tooling range has features such as variable pitch, helix, and patented rake and edge preparations. These features, combined with the highestquality substrates and coatings, result in tools that maximise metal removal rates, thus reducing cycle times, and and therefore improving productivity.

Using the same geometries and quality substrates as in our high-performance range, SGS has developed a high feed cutter solution that combines small depths of cut with high feed rates resulting in increased metal removal when compared to conventional milling. The increased feed rates can significantly reduce cycle times when machining tibial tray components, whilst the stability of this type of tool helps to maximise surface quality and tool life.

H-Carb milling solution

Tibial Tray Solutions

SGS TIBIAL TRAY SOLUTIONS

Our new H-Carb product range is ideally suited for high-speed roughing (profiling, trochoidal, dynamic) machining of titanium and cobalt chrome. The lower cutting forces generated by the H-Carb make them ideal for lower-powered machines and components with lower clamping / work-holding.

Profile machining Application Details Operation

Solution Advantages Cutting Data - Ø8mm

Profiling outer diameter

Speed

Requirement

Tool life and lower cost per part

Feed

2300 mm/min

Tool

H-Carb tool Ø8mm

Radial (ae)

1.0 mm

Cobalt Chrome

Depth (ap)

Material Coolant

Emulsion - Flood

Tool life

100 m/min

9 Cycle time reduction 9 Lower tooling cost 9 Long tool life (3h recorded) 9 Improved productivity

Floor machining of tray Application Details Operation

Solution Advantages

Cutting Data - Ø12mm

Finishing floor of tray

Speed

Requirement

Cycle time reduction and process stability

Feed

3000 mm/min

Tool

SGS high-feed tool - Ø12mm

Radial (ae)

6.0 mm

Material

Cobalt Chrome

Depth (ap)

0.3 mm

Coolant

Emulsion - Flood

Tool life

200 parts

6.0 mm

50 m/min

9 Stable process 9 Increased metal removal rates 9 Improved cycle times 9 Multiple regrinds available

3 hours

Result: Cost per part saving of 43% and increased tool life

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Result: Reduction in scrap of 22% and increased feed rates

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Acetabular cup

Replacement Hip Components

REPLACEMENT HIP COMPONENTS

Hip stem Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

HIP STEM SOLUTIONS

Hip replacement is currently one of the most common orthopaedic operations and is generally conducted to relieve arthritis pain and overcome hip fractures.

Through a combination of patented geometries, high-quality substrates, and coatings, SGS has developed market-leading tools that return tool life measured in hours as opposed to minutes when machining materials such as titanium and cobalt chrome.

Hip replacement generally consists of three parts: the acetabular cup, the femoral component and the articular interface. Femoral hip stems are manufactured from a variety of difficult-to-machine materials such as titanium and cobalt chrome and can be single piece or modular.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Hip Stem Components

HIP STEM COMPONENTS

SGS HIP STEM SOLUTIONS

Milling of titanium and cobalt chrome

Drilling of titanium and cobalt chrome

SGS have a range of 3, 4, 5, 6 and 7-flute tooling solutions suitable for slotting, profiling and dynamic milling of difficult-to-machine materials such as titanium and cobalt chrome.

The Hi-PerCarb Series 135 drill features a double margin design that can remove the need for reamers, whilst other design features are engineered to maximise chip control, drill strength, penetration rates, and therefore productivity.

Each tool in the SGS high-performance tool range has specific design features such as variable pitch, helix and rake angle, all aimed at reducing resonance, vibration and chatter, the main causes of premature tool failure.

The ICe-Carb Series 140 drill features an internal coolant design that allows for better control of machining temperatures and chips when machining materials such as titanium. The ICe-Carb drills’ design features reduce cutting loads, increase operating parameters and enhance tool life.

Z5 HPR milling solution SGS’s Z5 HPR tool solution is ideal for achieving high material removal rates (MRR) and a finish of 1.8Ra or better in most materials. The specialised 5-flute design is engineered for increased productivity over 3 and 4-flute end mills, whilst its variable geometry design allows for improved chatter suppression for improved tool life. Tool life and productivity is further enhanced via a through coolant option and coatings ideally suited for machining titanium.

Profile machining

Combi-drill solution SGS’s combi-drill solutions offer a reduction in the number of tools required for each hole. The drilling of stepped holes and chamfers can now be combined into one tool that delivers a stable, accurate process that reduces both cycle times and tooling costs.

Solution Advantages

Application Details

Cutting Data - Ø12mm

Operation

Rough outer diameter

Speed

Requirement

Cycle time reduction and tool life improvement

Feed

600 mm/min

Tool

Z5 HPR tool Ø12mm

Radial (ae)

Material

Titanium

Coolant

Emulsion - Through tool coolant

80 m/min

Hip Stem Solutions

SGS HIP STEM SOLUTIONS

9 Maximised profitability

Step drilling Application Details

9 Improved productivity 9 Maximum tool life

Solution Advantages Cutting Data - Ø5mm and Chamfer

Operation

Drilling of hip stem

Speed

40 m/min

Requirement

Tool cost reduction and dimensional accuracy

Feed

150 mm/min

1.0 mm

Tool

SGS combi-drill Ø5mm and chamfer

Radial (ae)

Ø5.0 mm

Depth (ap)

15.0 mm

Material

Titanium

Depth (ap)

15.0 mm

Tool life

4 hours

Coolant

Emulsion - Through tool coolant

Tool life

300 parts

9 Lower cost per part

Result: Cycle time reduction of 31% and tool life increase of 132% Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

9 One hit solution 9 Reduction in number of tools 9 Lower tooling costs 9 Increased tool carousel capacity

Result: Tool cost saving of 34% and dimensional accuracy improvement Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

ACETABULAR CUP SOLUTIONS

The acetabulum is a cup-like socket formed by the connection of the three bones that combine to form our hip.

Multiple tooling solutions and strategies are employed when machining these complex components.

This component is one of the most difficult medical implants to machine due to complex features, tight tolerances, thin walls, and being produced from materials such as titanium and cobalt chrome.

SGS has a comprehensive range of drills and end mills suitable for machining these titanium and cobalt chrome implants. SGS’s patented Multi-tool solutions can also be used to combine the machining of some features with one tool, thus reducing cycle times.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Acetabular Cup Components

ACETABULAR CUP COMPONENTS

ACETABULAR CUP SOLUTIONS

Milling of Acetabular cup components

Combi-tool solution

SGS’s well-established market-leading range of high-performance tooling is well suited to the challenges presented by difficult-tomachine materials such as titanium and cobalt chrome. Working with major medical implant manufacturers SGS have adapted and refined this range of tooling to ensure that cutting data is maximised whilst simultaneously increasing tool life.

SGS’s patented one-shot combi-tool drilling and milling solutions offer a reduction in the number of tools required for each hole. The drilling and milling of holes, counterbores and chamfers can now be combined into one tool that delivers a stable, accurate process and reduces both cycle times and tooling costs.

More recently we have developed geometries, edge preparations and flute polishing techniques specifically aimed at machining titanium with C02 gas or even dry.

In addition, the combi-tool can also deliver production savings by reducing set-up and tool change times and can offer other advantages such as freeing up space in tooling carousels.

Series 33 milling solution SGS’s Series 33 solution is good for slotting and pocketing difficult medical materials and is ideal for applications where swarf evacuation is a problem. It has a 3-flute variable geometry design for vibration reduction that also gives excellent chip control. The tool has a stepped core for rigidity and is suitable for plunging applications and ramping.

Slot machining

Hole machining Solution Advantages

Application Details

Cutting Data - Ø6mm

Operation

Locking slot machining

Speed

70 m/min

Requirement

Tool life increase and tool cost reduction

Feed

250 mm/min

Tool

Ser-33 tool - Ø6mm

Radial (ae)

6.0 mm

Material

Titanium

Depth (ap)

6.0 mm

Coolant

Co2 gas - External delivery

Tool life

3 hours

Application Details

9 Improved productivity 9 Lower tooling costs 9 Lower cost per part

Result: Tool life increase of 123% and tool cost reduction of 40% Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Solution Advantages Cutting Data Ø6.5mm / C-Sink and back chamfer

9 One hit solution

9 Additional space in tool carousel

Operation

Machining of bone screw holes

Speed

45 m/min

Requirement

Cycle time and stable process

Feed

150 mm/min

Tool

SGS combi-tool Ø6.5mm/countersink and back-chamfer

Radial (ae)

Ø6.5 mm

Material

Titanium

Depth (ap)

8.0 mm

Coolant

Co2 gas - Through tool delivery

Tool life

220 parts

9 Reduced tool changes

Acetabular Cup Solutions

ACETABULAR CUP SOLUTIONS

9 Combines operations 9 Stable, accurate process

Result: One hit solution with cycle time reduction of 67% Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Trauma Plates

Trauma and Spinal Components

TRAUMA AND SPINAL COMPONENTS

Spinal Plates

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

TRAUMA AND SPINAL SOLUTIONS

Trauma plates come in many shapes and sizes and are manufactured from biomaterials such as titanium, various stainless steels and cobalt chrome. Plates for fractures are designed to follow the natural contours of the bone and are screwed into place holding the bone pieces together whilst they heal.

The variety and complexity of design of trauma and spinal plate components dictates that multiple tooling solutions and strategies are employed when machining them.

Spinal plate implants are manufactured from the same materials and are designed to decompress and stabilise the spine. SGS has a full range of high-performance end mills and drills well suited to the machining of these complex components.Â

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

SGS has developed comprehensive range of milling cutters and drills suitable for producing these titanium, stainless steels and cobalt chrome plates. In addition, we have developed special tooling including high-feed tools, and our patented combi-tool solutions.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Trauma and Spinal Solutions

TRAUMA AND SPINAL COMPONENTS

TRAUMA AND SPINAL SOLUTIONS Drilling of titanium and cobalt chrome

Milling of trauma plate components

SGS has a range of high-performance drilling solutions including our Hi-PerCarb and through-coolant ICe-Carb ranges. The Hi-PerCarb drill features a double margin design that can remove the need for reamers, whilst other design features are engineered to maximise chip control, drill strength, penetration rates, and therefore productivity.

SGS have a range of 3, 4, 5, 6 and 7-flute tooling solutions suitable for slotting, profiling and dynamic milling of difficult-to-machine materials such as titanium, cobalt chrome and stainless steels. Working with major medical implant manufacturers we have adapted and refined our high-performance range of tooling to ensure that cutting data is maximised whilst simultaneously increasing tool life.

The ICe-Carb Series 140 drill features an internal coolant design that allows for better control of machining temperatures and chips when machining materials such as titanium. The ICe-Carb drills design features reduce cutting loads, increase operating parameters and enhance tool life.

V-Carb milling solution SGS’s V-Carb solution is ideal for profiling and finishing of difficult medical materials.

Hi-PerCarb drill solution Features such as a double margin, secondary flute, and Specialized 145° notched point give the Hi-PerCarb drill the ability to maximise chip control and penetration rates. A self centering point geometry can also eliminate the need for spot drilling. The Hi-PerCarb drill range is available in 3xD and 5xD versions and in Metric, Fractional, Letter and Number sizes and in diameters Ø0.40mm to Ø16.0mm

Our 5-flute design also makes it suitable for trochoidal / dynamic machining strategies. As with all SGS’s high-performance tooling the V-Carb range has a variable geometry design for vibration reduction. The V-Carb range is available in stub, regular and long flute lengths, and also with a ball-end version ideal for scanning.

Finish machining

Solution Advantages

Application Details

Cutting Data - Ø12mm

Operation

Speed

Finishing of plate face

135 m/min

Requirement

Cycle time and surface finish

Feed

1470 mm/min

Tool

V-Carb tool Ø12mm

Radial (ae)

0.5 mm

Material

316L Stainless steel

Depth (ap)

28.0 mm

Coolant

Emulsion - Flood

Tool life

2.5 hours

9 Maximised profitability 9 Multiple regrinds available

Hole machining

Solution Advantages 9 Superior hole quality

9 Superior surface finish

Application Details

Cutting Data - Ø6mm

9 High feed rates

Operation

Drilling of bone screw holes

Speed

Requirement

Cost per part reduction

Feed

180 mm/min

Tool

SGS Hi-PerCarb drill - Ø6mm

Radial (ae)

Ø6.0 mm

Material

Titanium

Depth (ap)

5.0 mm

Coolant

Emulsion - Flood

Tool life

58 mins

Result: Cycle time reduction of 34% whilst maintaining surface finish requirement

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Trauma and Spinal Solutions

TRAUMA AND SPINAL SOLUTIONS

40 m/min

9 Improved tool life 9 Improved productivity 9 Removal of reaming process

Result: Cost per part reduction of 38% and improved hole quality Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Dental Implant Components

DENTAL IMPLANT COMPONENTS

DENTAL IMPLANT SOLUTIONS

Dental implants generally consist of three parts, the implant, the abutment and the crown. Additionally, dental work may also include the fitting of bridges and bars.

By their very nature dental implants tend to be small, complex and customised to suit the individual’s mouth, and therefore require multiple small/micro tooling solutions and strategies to be employed when machining them.

The Implant The implant is a small titanium screw that is positioned into the jawbone beneath the gum and acts as an artificial root. The implant serves as a base for fixing individual ‘teeth’ or a multi-tooth bridge.

SGS’s range of high-performance end mills and drills are available in sizes as small as Ø1.0mm and have the same design features as our larger tools, including variable pitch, helix and rake angle, all aimed at reducing

resonance, vibration and chatter, the main cause of premature tool failure. In addition, SGS has developed a comprehensive range of micro end mills suitable for producing these titanium, cobalt chrome and zirconia components. Our micro tool range starts at Ø0.1mm and is available in both square and ball end solutions and in various cut lengths up to 12xD.

Dental Implant Solutions

DENTAL IMPLANT COMPONENTS

The Abutment The abutment connects the implant to the crown and can be made from several materials such as titanium and zirconia.

The Crown The crown is the replacement tooth and is the only part you see in the mouth. Screwed directly into the abutment, crowns can be made from a variety of metals and composites, including porcelain, ceramic, acrylic, or metal alloys.

Bridges and Bars Support several replacement teeth and are produced from materials such as titanium and zirconia. The components are customised to suit the individual's mouth.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

DENTAL IMPLANT SOLUTIONS

Milling of dental implants

Micro tool milling solutions In recent years SGS have turned attention to the micro tool market and introduced a comprehensive range of highperformance quality tools.

SGS has a comprehensive range of high-performance end mills suitable for machining these small complex components. Our range of tools start as small Ø0.1mm and has the same design features as our larger tools including variable pitch, helix and rake angle. All these design features are aimed at maximising metal removal rates, thus reducing cycle times, therefore improving productivity.

During an extensive testing and development process we identified advanced geometries that extend tool life, reduce chatter, cut cycle times and improve part quality. We also identified a coating that not only gives these micro tools a 250% life increase over the competition but increases chip flow even in low RPM applications.

Z-Carb milling solution With the introduction of the patented Z-Carb range of tools back in 2000, SGS became the first cutting tool manufacturer to launch variable geometry tooling on to the market.

Our specially selected substrate is inspected at our in-house metallurgical lab prior to manufacturing to ensure only the highest-quality carbide is turned into your precision micro tool. Our micro tool range includes both metric and fractional square and ball end products and is available in diameters from Ø0.1mm to Ø3.0mm, and in various cut lengths up to 12xD.

The launch of the Z-Carb AP range with its patented variable rake geometry further improved the tool's ability to maximise metal removal rates, thus reducing cycle times, and therefore improving productivity. In subsequent years SGS have added several variants to the Z-Carb family, creating one of our most comprehensive ranges. The Z-Carb range is available in sizes as small as Ø1.0mm and has the same variable design features as our larger tools.

Crown roughing

We believe that these tools, albeit small, are a huge step forward for micro machining.

Solution Advantages

Crown finishing

Solution Advantages

9 High metal removal rates

Application Details

Cutting Data - Ø1.0mm

Operation

Speed

Requirement

Crown roughing

110 m/min

Cost per part reduction and process stability

Feed

Tool

Z-Carb tool - Ø1.0mm

Radial (ae)

0.3 mm

Material

Titanium

Depth (ap)

2.0 mm

Coolant

Emulsion - Flood

Tool life

1.5 hours

Dental Implant Solutions

DENTAL IMPLANT SOLUTIONS

9 Improved productivity 9 Stable process 9 Lower tooling costs

280 mm/min

Result: Cost per part reduction of 76% whilst reducing the amount of scrap Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Application Details

Cutting Data - Ø1.0mm

9 Improved componenet quality

Operation

Speed

9 Stable process

Crown finishing

80 m/min

9 Superior surface finish Requirement

Surface finish

Feed

200 mm/min

Tool

Micro ball-end tool - Ø1.0mm

Radial (ae)

0.1mm

Material

Titanium

Depth (ap)

0.06 mm

Coolant

Emulsion - Flood

Tool life

1 hour

9 Lower process costs

Result: Improved cutting data whilst maintaining surface finish requirement

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Our European office specialises in bespoke tooling designed to suit specific medical application criteria. When developing our solutions, we consider all aspects of tool design including geometry, carbide grade, edge preparation and coating.

Working closely with medical implant manufacturers we have developed many new and innovative milling and drilling solutions designed specifically to overcome the challenges faced by the medical market.

We often develop specific special solutions on components supplied by our customers and test proposed tooling using our in-house MultiAxis CNC milling machines, whilst also utilising the latest technology in spindle monitoring and high magnification measuring equipment.

T-Slot cutter | Suitable for Polyethylene

Taper ball nose tool | Suitable for Titanium, Cobalt Chrome and Stainless Steel

Form cutter | Suitable for Polyethylene

Combi-mill | Suitable for Titanium, Cobalt Chrome and Stainless Steel

Lollipop cutter | Suitable for Polyethylene

De-burring tool | Suitable for Titanium, Cobalt Chrome and Stainless Steel

Step drill | Suitable for Titanium

T-Slot cutter | Suitable for Titanium, Cobalt Chrome and Stainless Steel

Step drill | Suitable for Polyethylene

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

SGS Special Medical Solutions

SPECIAL

Established in 2012, Kyocera Hardcoating Technologies provides premium PVD coating solutions to a broad spectrum of industries in the UK and across Europe. We also have a facility in North America with dedicated coating scientists and a laboratory.

Coating Titanium Nitride (TiN)

Through testing and development, both teams focus on the latest technical competence and coating techniques to bring a continuous stream of advancements to the market.

Aluminum Titanium Nitride (AlTiN)

Here in the UK we are equipped with HiPIMS (Hi Power Impulse Magnetron Sputter) technology. This allows us to offer some of the highest performance PVD coatings, for the most demanding medical implant applications.

Titanium DiBoride (TiB2)

Titanium Carbonitride (TiCN)

Identifying Color

gold

dark grey

light grey-silver

pink-red

Layer Structure

Thickness

Multilayer 1–5 microns

Nano structure

1–5 microns

Monolayer 1–2 microns

Multilayer 1–5 microns

Coefficient Hardness of Friction (HV) (Fretting)

2200

3700

4000

3000

0.4–0.65

0.30

Our coating

Competitor coating

Material safety data sheet (MSDS)

Proprietary (TX)

Crystalline Diamond (Diamond)

black

Nano 1–5 microns Composite

Monolayer

6–20 microns

3600

>8000

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

copper

Nano 1–5 microns Composite

3600

A general purpose coating with good adhesion and abrasion resistant properties. Suitable for a wide variety of materials.

Excellent thermal and chemical resistance allows for dry cutting 1100°C / and improvements in performance 2010°F of carbide. The coating has a high hardness giving great protection against abrasive wear and erosion.

0.45

850°C / 1562°F

0.3–0.45

400°C / 752°F

A very wear resistant coating with high toughness and shock resistance. Good in interrupted cuts found in applications like milling.

0.45

0.15–0.2

Hardcoating Technologies can supply MSDS sheets for all our coatings on request. Proprietary (TM)

600°C / 1112°F

This ceramic based coating ensures a smooth surface and a low affinity to cold welding or edge build up, which makes it optimal for Aluminum and copper applications. It has high toughness and high hardness.

Our coatings Increase surface hardness and heat resistance while reducing built-up edge, galling and fracture. These characteristics allow for elevated cutting data whilst at the same time delivering increased tool life.

Thermal General Information Stability

0.45

Hardcoating Technologies

Ti-NAMITE® and Di-NAMITE® Tool Coatings are specifically engineered for KSPT solid carbide rotary tools. The coating lineup includes proprietary processes that result in optimized tool life and increased speed and feed rates in a variety of applications.

The structural design of Ti-Namite-X is adapted to meet a diverse range of applications; everything from high- and low-alloy 1150°C / steels to hardened materials 2100°F (up to 65 HRC core hardness). Ti-Namite-X is suitable for operations which require high cutting speeds, high temperatures at the cutting edge, and high metal removal rates.

800°C / 1470°F

This is the hardest coating available with the best abrasion resistance. It is carbon based so it is limited in application capabilities. This coating is suitable for machining highly abrasive, non-ferrous materials such as CFRP and graphite.

Features include high wear resistance, reduced friction, and excellent prevention of edge build 1150°C / up. This coating provides superior 2100°F material removal rates and tool life when used in high performance operations with difficult to machine materials like Titanium.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Catalogues and Brochures

CATALOGUES AND BROCHURES View the following and more on our website:

Global Product Catalogue - metric

www.kyocera-sgstool.co.uk/resources/brochures

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

Technical Services

TECHNICAL SERVICES

Process Development

Bespoke Tooling Solutions

SGS tech hubs can help get the best from our high-performance range of tooling, by applying the correct tools and optimum strategies.

SGS R&D can develop specific tooling unique to your requirements, through extensive knowledge and creative thinking.

Using our in-house Multi-Axis CNC milling machines we can perfect a process working in conjunction with our partners.

Using the latest technology in spindle monitoring and high magnification measuring equipment, we can develop tooling to suit your application and material specification.

Whether it be machine tools, tool holding, work holding or Software suppliers of the latest CAD-CAM, we are committed to help find the best solution.

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

REGRIND, RECOAT AND ALTERATION SERVICES.

Create a better way.

Regrind, Recoat and Alteration Services

Re-manufactured to original geometry. Before

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

After

SGS Tool Wizard

An intuitive three-step process of selecting Material, Application and Tool allows for a seamless transition from the legacy Tool Wizard® platform.

Features include: • Updated CAD models displaying tool application scenarios for an enhanced user experience. • Dynamic filters that allow the user to easily find the optimal tool at the click of a button. • Enhance shop productivity by using KSPT calculated speed and feed recommendations with the new feature allowing for the adjustment of RPM and IPM parameters. • Save time and time drive efficiencies by referencing historical searches to access previous calculations and print results.

REGISTER TO ACCESS OVER 12,000 SGS STANDARD CATALOGUE TOOLS Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200

KYOCERA SGS Precision Tools Europe Ltd 10 Ashville Way, Wokingham, Berkshire RG41 2PL +44 (0) 1189 795 200 saleseu@kyocera-sgstool.com www.kyocera-sgstool.co.uk KYOCERA SGS Precision Tools Europe Ltd KSPTE

Kyocera SGS Precision Tools Europe Ltd | www.kyocera-sgstool.co.uk | +44 (0) 1189 795 200