5-Axis Medical Machining

March 15, 2021

CNC drill touching down

Having a 5-axis machine offers tremendous advantages in the processing of medical and surgical parts such as dental, knee, hip, and spine implants and surgical instruments; just to name a few medical applications. Part handling can be greatly reduced using 5-axis milling machines to complete complex parts in a single setup which reduces lead time and increases shop efficiency and leads to higher workflow predictability. Often three or more setups with expensive fixtures would be required to process work on 3 or 4-axis machines with the resultant loss of accuracy each time the part is relocated for subsequent operations.

The GenMill 5X-12 is a full-featured high-performance 5-Axis simultaneous milling machine, featuring glass scale feedback in all 5-axes to ensure accuracy. The 12.6” platter diameter tilting rotary trunnion table is driven by a precision worm-gear, and provides 150-degrees of tilt motion and 0.001-degree indexing resolution. The GenMill 5X-12 eliminates setups by allowing you to machine multiple sides of the workpiece in just one operation, without relocating the part or fabrication expensive fixtures, as well as allowing you to handle parts that require full 5-axis simultaneous machining.

Interior of GENMILL 5X-12

Standard features include a 12,000 RPM high-performance Big-Plus dual-contact precision ground #40-taper spindle for extra tool rigidity and accurate tool length repeatability.  The rigidity of the dual-contact tool clamping system enhances tool life which leads to increased productivity.   The standard coolant system provides 300-PSI through-the-tool coolant flow and a separate coolant pump is supplied  for chip washdown to efficiently move chips into the belt-style chip conveyor.  A 40-tool chain drive twin-arm tool changer delivers tools in in just 1.7-seconds (tool-to-tool) providing fast tool changes with ample tooling availability for complex workpieces.  Rapid traverse rates of 1,417 IPM reduce cycle time providing for efficient production.  High-speed synchronous rigid tapping is another included production enhancement.

Certified medical materials are often challenging to machine.  Materials such as Invar, Kovar, Inconel, and titanium alloys required a rigid machine with the workpiece rigidly held and ample stiffness in the spindle.  The GenMill 5X-12 addresses this issue with added stiffness provided by the heavy-duty cross-roller style way system in the 3-linear axes providing the needed rigidity and enhanced cutting accuracy and helps extend tool life.  The heavy-duty cross-roller way system provides over twice the rigidity offered by the standard ball-style liner ways used in typical machines. The machine is constructed of all certified premium grade high-density Meehanite castings and weighs over 15,700 pounds for superb vibration dampening that extends tool life. The wide spacing of the ways offers the optimal guide ratio for the moving elements further enhancing the rugged design of the machine for accurate and heavy-duty machining.

GENMILL 5X-12 against a white background

The rigidity of the high-strength cast iron frame provides a high-strength cutting platform with superior vibration dampening for improved surface finish & extended tool life. The blending of strength with speed provides the ultimate value enhancing combination with the 12,000-rpm Big-Plus spindle making the machine ideal for medical grade materials and the strength of the cross-roller ways providing the rigidity for efficient machining of Inconel and stainless.  The GenMill 5X-12 was designed to provide the dynamic results shops are looking for to efficiently process their multi-faced or five-axis work profitability. 

Visit expandmachiney.com or contact Expand Machinery in Chatsworth, CA at 818-349-9166 for further information.

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