In the intricate world of medical device manufacturing, where precision is paramount and innovation saves lives, a strong production process is key. From crafting tiny bone screws to fabricating complex hip replacement parts, there is high demand for accuracy, reliability and efficiency.

The medical device industry encompasses a wide array of products designed to diagnose, monitor and treat medical conditions. From diagnostic equipment to implantable devices, the industry caters to the evolving needs of healthcare professionals and patients worldwide.

Today, there are an estimated two million different kinds of medical devices on the global market, categorised into more than 7,000 device groups, according to the World Health Organisation (WHO).

Challenges In Medical Device Manufacturing

Manufacturing components for medical devices presents unique challenges that demand advanced machining solutions. End-users rely on these devices being manufactured to the highest quality, as any products that do not meet quality standards can cause huge disruption. Entire operations could be paused, products recalled, organisational reputation damaged and patients’ lives at risk.

Additionally, regulatory requirements are stringent in this field. There are international standards around quality management — such as ISO 13485, risk management and ISO 14971 — as well as regional regulations such as 21 CFR and FDA for the US and EU MDR for the European Union, which all devices must meet.

The requirement for such high accuracy means manufacturers cannot risk even a millimetre of differentiation between components, so having a robust machining setup is paramount.

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Despite 2023 being a challenging year for manufacturers, global manufacturing output is set to achieve a compound annual growth rate of 3% between now and 2027 according to technology insight business Interact Analysis. From digitalisation and demand forecasting to economic uncertainty and emissions targets, 2023 presented several challenges for the manufacturing industry. However, these difficulties also provide opportunities for manufacturers to innovate and increase their competitiveness as the industry transforms.

Strengthened Sustainability Focus

The focus on reducing our environmental impact intensified in 2023, with IBM’s Institute for Business Value data showing 86% of companies now have a sustainability strategy in place. While this figure is promising, data shows that only around a third of businesses have acted on their strategy since its implementation.

2024 will hopefully see the rise of businesses treating sustainability as a priority. This is especially important within the manufacturing industry, which is responsible for one-fifth of global carbon emissions according to World Economic Forum data. Currently, the sector is not sustainable enough, and we can do a lot more.

Ensuring that sustainability is not just a strategic ambition but a tangible, integrated part of daily operations is key to reducing emissions and achieving green targets. By combining strategic alignment, employee engagement and continuous data-driven improvements, manufacturers can not only achieve environmental and social goals but also drive innovation, reduce costs and enhance the company’s reputation and competitiveness.

Sandvik Coromant’s new brand promise of Manufacturing Wellness is a multifaceted approach which aims to drive sustainable progress through impactful partnerships. Manufacturing Wellness is a relentless pursuit for improvement, made up of eight habits found in successful and resilient manufacturing companies.

Sustainability and eliminating waste are the third and fourth habits of this mindset, which allows us to drive sustainable progress towards a better tomorrow for people, industry and society at large. Another one of our eight habits that make up this movement is embracing new technology.

Sandvik Coromant aims to deliver a strong understanding about the value that technology adoption can have. Adopting advanced technology allows manufacturing companies to enhance efficiency, elevate product standards, minimise costs and remain at the forefront of a competitive landscape.

In doing so, they stand better prepared to anticipate and face challenges as and when they arrive. Through the integration of new technological solutions, manufacturers can optimise their operations, embrace automation and maintain a leading position in a swiftly changing sector. 

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Historically, the way that companies measure sustainability has been subject to accusations that it is fluff rather than fact. That’s because, in the past, metrics haven’t been held in the same regard as other business metrics, such as financial data. But that’s all set to change.

At the UN’s COP28 climate conference in 2023, world leaders debated what an agreement to end the use of fossil fuels could look like. In the end, it was agreed the world would work towards “transitioning away from fossil fuels in energy systems in a just, orderly and equitable manner”.

While a step away from initial discourse around the complete ‘phasing out’ of fossil fuels, the very inclusion of fossil fuels in net zero plans was seen as a landmark moment. Accounting for one-fifth of global carbon emissions and 54% of the world’s energy usage, tackling fossil fuel reliance in the manufacturing and production sector will undoubtedly support global environmental goals.

The Detail Is In The Data

Businesses that focus on sustainability tend to see great rewards. Embedding metrics such as waste generation, carbon emissions and energy usage into business strategy is essential to meeting customer demand, regulatory requirements and investor preferences.

An emphasis on sustainability has also been proven to attract top talent, reduce costs and boost financial profits. However, despite its benefits, businesses still struggle to showcase their credentials. Research published by the World Economic Forum revealed that, while 90% of executives believe sustainability is important, only 60% of organisations have sustainability strategies in place.

What’s the biggest sticking point? To paraphrase Drucker, what’s not being measured, simply cannot be improved upon. To reduce reliance on fossil fuels, tackle greenhouse gas emissions and limit the production of waste, manufacturers need access to the right data.

Read more here at page 16

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A new record for the number of people in space all at once was set in May 2023, with 20 people simultaneously in orbit. Among the many space missions that have taken place last year, Virgin Galactic’s Galactic 01 marked the first commercial suborbital spaceflight mission for the company, with SpaceX also gearing up for its first commercial spacewalk. From space tourism to rocket innovation, man is diving deeper into the great black.

We have seen several giant leaps for mankind in recent years. The European Space Agency’s JUpiter ICy moons Explorer (JUICE) mission launched in April 2023 and is set to arrive in the Jovian System in 2030.

It will then take three-and-a-half years to observe Jupiter’s three moons. Roughly 100 launches are also planned by SpaceX this year, and NASA’s OSIRIS-Rex has recently returned to Earth in September 2023. And that’s just a handful of the recent, current and future projects aiming to help us know more about our galaxy.

Ensuring success among the stars takes many considerations. Be it thorough mission planning, rigorous simulation, qualified mission managers or effective contingency planning, a successful space trip requires careful planning, preparation and execution.

Additionally, materials used in space applications must withstand some of the most extreme conditions one could imagine — such as vacuum, radiation, thermal cycling and micrometeoroid impacts.

Tough Materials

Building anything destined for space involves a range of material considerations to ensure its safety, performance and functionality in extreme conditions. Structurally, materials must be able to withstand high pressures and stresses experienced during launch and in-flight.

Spacecraft will also experience intense heat during re-entry to the Earth’s atmosphere and so external materials must work to stop the vehicle burning up, while other components, such as rocket nozzles, must also be made from heat resistant materials.

Weight is also a consideration, particularly for elements such as rocket propellant tanks where a lighter tank can better withstand structural stresses and can aid with payload capacity. The more the rocket itself weighs, the less payload, including satellites, scientific instruments and crew, it can carry into space. Lighter tanks allow for a larger portion of the rocket’s total weight to be allocated to payload, maximising the mission’s capabilities.

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Research by Schneider Electric and Omdia found 49% of manufacturing companies expect improved performance and cost savings when investing in sustainability. While the conversation around manufacturing sustainability usually focuses on Industry 4.0 solutions, companies must not overlook the significant role that machine tools like coated solid carbide end mills play.

Machine shops now realise that a proper sustainability strategy differentiates success and failure — especially in light of today’s continuing supply chain challenges, and shortages both of materials, knowledge and skills. However, roadblocks stand in the way of manufacturing becoming more sustainable.

Almost a third of manufacturing leaders surveyed by Schneider Electric and Omdia said their organisations legacy assets and infrastructure are an obstacle to becoming greener. 27% identified cost or budget is a key roadblock, and 19% cited culture change as a challenge, or the risk of changing their existing processes.

Manufacturers should consider the significant advantages of better machine tools on production sustainability. Longer tool life can certainly support sustainable machining and ties into a number of other advantages, including reducing the number of tools required in a production run and reducing the need for costly tool replacements.

Another advantage of longer-lasting tools is the ability to produce more versatile products for two reasons. First, a tool with a longer lifespan can be used for a greater number of production cycles before it needs to be replaced or serviced. Second, with longer tool life, the tool maintains its precision and performance over an extended period, which results in improved quality and consistency of the products being produced.

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Recognising the ever-changing landscape of its industry, Sandvik Coromant has strategically transformed its operations in recent years, emphasising applied knowledge and cutting-edge capabilities. Driven by a shared passion for engineering and problem-solving, Sandvik Coromant is united with its customers and partners in a pursuit of innovation and improvements.

This spirit of collaboration and progress inspired the quest for a new brand identity geared for today’s and tomorrow’s digital demands that encapsulates the essence of its broader approach and extensive range of offerings.

“We firmly believe that success is not solely measured by business results, also our positive influence on our communities and the world at large. And we wanted an identity that truly captures that, and the essence of our organisation’s values and aspirations,” says Helen Blomqvist, President at Sandvik Coromant.

Sandvik Coromant provides unparalleled support, equipping its business collaborators with the necessary knowledge and advanced technology required for healthy manufacturing habits and the creation of sustainable businesses. Manufacturing wellness holds the spirit of solid and successful manufacturing businesses – that not only focus on success in their own operations but also contribute positively on people and societies.

“Manufacturing Wellness serves as a compass guiding us toward a future where resilient, thriving enterprises and sustainability go hand in hand. By adopting this approach, Sandvik Coromant aims to foster an environment of healthy manufacturing habits and facilitate the development of sustainable businesses,” Helen continues.

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The demands on manufacturers can be summed up as: ‘produce innovative and higher quality product s in shorter time.’ Add sustainability initiatives into the mix, and it becomes clear that manufacturers in all sectors must apply comprehensive strategies to overcome these obstacles while staying ahead of the competition.

“We should not prioritise on the basis of project profitability,” wrote the best-selling product development author Donald G. Reinertsen, “but rather on how this profitability is affected by delay.”

Manufacturers are expected to accelerate product development cycles to meet rapidly-changing market demands — yet they are also losing hundreds of production hours to equipment downtime and unnecessary tool changes.

Understanding Comprehensive Strategy

What does a ‘comprehensive strategy’ entail on the machine shop floor? Antidotes to rising energy and commodity prices, suggested in PwC’s “Achieving Excellence In Production And Supply Report”, noted companies should monitor and optimise their processes to make them as efficient as possible.

This also means manufacturers should accelerate their product development cycles to meet rapidly heightening performance and safety
standards. One approach is through on demand manufacturing, where goods are delivered precisely in accordance customers’ specifications in certain quantities.

On-demand manufacturing is made possible by latest additive manufacturing (AM) technologies, like 3D printing, which speeds up
manufacturing and prototyping. Elsewhere, manufacturers use artificial intelligence (AI) and Industry 4.0 concepts to optimise their processes.

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Cutting tool specialist Sandvik Coromant is expanding its line of CoroMill^® Dura versatile solid end mills with aluminium-specific tools.

“These new truly versatile end mills for aluminium machining are developed for excellent capabilities in all applications”, says Antti Wikström, Global Product Manager, Solid end mills at Sandvik Coromant. “The very stable cutting, small burr, good surfaces and minimal vibrations is a combination hard to beat for a versatile end mill like this.”

“One of the main advantages with the new CoroMill^® Dura aluminium-specific end mills is their versatile performance in all different types of roughing applications, while also offering finishing capabilities”, Wikström continues. “Up to 2×D full slot, pocketing, 5–20° ramping, shoulder milling and more — all with the same end mill.”

Another advantage is Sandvik Coromant’s unique helix concept WhisperKut — where each flute is carefully oriented, unequally spaced from the others and has its own individually adapted helix angle, effectively breaking up harmful harmonics. This design successfully eliminates vibrations, resulting in silent, safe and efficient machining.

The standard assortment offers diameters from 2–25 mm, depths of cut between 1.5–3×D, neck options, extended reach cutters, sharp and corner radius. Tailor Made^® options include coated grades for more abrasive aluminiums, specific diameters, corner designs and shank options.

To make tool selection easier, online tool selector CoroPlus^® Tool Guide for CoroMill^® Dura assists with tool and cutting data recommendations.

”Having the right cutting data is of course a prerequisite for both secure and efficient machining”, says Wikström. “In CoroPlus^® Tool Guide for CoroMill^® Dura we can give the most accurate starting values for a specific application. And if you have a CAM software with CoroPlus^® Tool guide plug-in it makes it even easier — you get the most relevant cutting data recommendations directly into your CAM program.”

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The global EV landscape is also more competitive than the automotive markets of previous decades, as more manufacturers — large and small compete for space. The rise of electrification is happening more widely and suddenly beyond anyone’s expectations, for automobiles plus other types of electric vehicles (EV).

How can manufacturers stay ahead of the EV competition while overcoming the increasing challenges posed by difficult-to-machine materials, like high strength steels?

The Automotive Revolution

From the mid-1930s, the “Big Three” manufacturers dominated the US automotive market: General Motors, Ford and Daimler Chrysler. This
continued for the next 70-plus years. Competition among carmakers is now changing — both within the US and in the current world leading markets for EVs: Asia Pacific, followed by Europe.

As written by Matthias Holweg in The Evolution of Competition in the Automotive Industry, a chapter from the book Build To Order: The Road to the 5-Day Car: “Competition has shifted from cost-leadership during the heyday of Ford’s original mass production, to variety and choice [and then] to diversification through leadership in design, technology or manufacturing excellence.”

This also applies to the EV markets. They are shaping-up to be more diverse and competitive than the automotive markets of yesteryear
as larger established companies, like Porsche, compete with small, globally-expanding manufacturers, like Polestar.

On the world stage, these companies need to catch-up with China — indeed, six of the ten best-selling plug-in EV worldwide were from Chinese brands in 2021, according to Statista.

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Although CSR is important, Sandvik Coromant estimates manufacturers waste between 10 and 30 percent of material in their machining processes, with a typical machining efficiency of below 50, which includes design, planning and cutting phases.

A survey by OpenText showed 92 percent of manufacturers consider corporate social responsibility (CSR) to be important for their market reputation. According to the 17 Global Goals for Sustainable Development set out by the United Nations (UN), manufacturers are expected to minimise their environmental impact while going further than just optimising energy use.

The UN’s goals recommend two main avenues taking into account such factors as a growing population, finite resources and the linear economy. The first is to address these challenges with technology.

Industry 4.0 concepts — like cyber physical systems, big data or the Internet of Things (IoT) — are frequently cited as the way forward for manufacturers seeking to reduce waste. Yet, most manufacturers have yet to apply modern machines with digital capabilities to their steel turning operations.

Most manufacturers are aware of how important the choice of insert grade — for making steel turning more efficient and productive; and how this affects overall performance and tool life. Nonetheless, many are omitting the whole tooling concept; everything from advanced inserts, tool-holders and easy-to-adopt digital solutions.

Each of these factors can help to make steel turning more sustainable by reducing energy consumption and minimising waste.

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