Laser-Cut Prosthetic Blanks With Integrated Hole Edge Sharpening
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Solution Overview
Problem
Current methods for producing prosthetic surgery instruments require multiple machinery steps, leading to inefficiencies, excessive waste, and the need for separate sharpening of laser-cut holes, which can cause repositioning errors and decrease productivity.
Innovation Solution
An automated laser cutting station that uses a laser cutting head to incline the edges of holes at specific angles, eliminating the need for subsequent sharpening and reducing waste, while increasing productivity through integrated laser cutting and edge sharpening in a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate sharpening machine is used after laser cutting, then edge sharpness is improved, but productivity decreases and repositioning errors occur
Solution Approach 1:
The patent combines the laser cutting function and edge sharpening function into a single laser cutting apparatus. The laser beam performs both cutting and sharpening operations sequentially on the same component without requiring transfer to another machine, thereby eliminating repositioning errors and increasing productivity while maintaining edge sharpness.
Solution Approach 2:
The laser cutting apparatus performs the sharpening action immediately after cutting the hole, while the component is still in position. This preliminary action of sharpening right after cutting eliminates the need for separate machining operations and repositioning, thus improving both precision and productivity.
2Manufacturing precision
If entire edge is sharpened in separate machine, then edge sharpness is improved, but material waste increases and surface strength decreases
Solution Approach 1:
The laser cutting apparatus applies the sharpening action locally only to the specific edges that require it, rather than sharpening the entire perimeter of the hole. The laser selectively sharpens only the necessary cutting edges while leaving other portions of the edge untouched, thereby minimizing material waste and preserving surface strength in non-critical areas.
3Manufacturing precision
If multiple machinery steps are used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The laser cutting apparatus is designed to perform multiple functions: cutting holes, sharpening edges, and creating complex cutting profiles. This multi-functional capability eliminates the need for multiple specialized machines (chip removal machine, sharpening machine, grinding machine, punching machine), thereby reducing device complexity while maintaining manufacturing precision through integrated operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated laser cutting station efficiently produces semi-finished components with pre-sharpened edges, reducing working times and material waste, and enhancing productivity by integrating laser cutting and edge sharpening in a single operation.
Implementation Method 1
a laser cutting head (20) configured to execute a plurality of laser cutting workings on one of the aforementioned untreated components (110)
Data Source
AI summary
An automated laser cutting station for the production of semi-finished components for prosthetic surgery instruments able, in use, to carry out tissue removal processes. Said automated station comprises at least a first automated operator, a laser cutting apparatus, and a control unit. The present invention also relates to a relative method for the production of such a semi-finished component, and to the semi-finished component thus obtained.