Manufacturing medical parts is no easy task. The complexity of the human body -- not to mention stringent standards imposed by FDA and others -- dictates the need for turnkey processes capable of producing highly intricate components to a finished state. To serve its customers, Omni specializes in multi-axis precision machining including M/A Swiss, M/A lathe, vertical milling, waterjet cutting, and turnkey assembly.
Recognizing the increased demand for medical components machining, Omni Components Corp, Hudson, NH, has boosted its business by increasing its share in the medical device industry. Today, manufacturing of medical-related components accounts for more than 20% of Omni''s overall business. This positive impact has led Omni to post its most successful year in its 25-year history -- and during a time when other manufacturers were scaling back or closing.
Much of its success in the medical industry can be attributed to Omni''s use of the Bengal abrasive waterjet cutting machine from Flow International. Using the Bengal, Omni can produce finished flat components or cut stock metals to near-net shapes. This technology enables difficult shapes to be produced at the pre-machine blank stage with minimal distortion, without heat-affected zones, and with maximum utilization of raw material.
Among the benefits Omni Components has realized as a result of using the Bengal waterjet cutting machine are:
Producing near-net shapes. An example is 1/4 in. thick Titanium (TI6AL-4V ELI) plate used in producing a medical application frame component with long slots and thin walls. The waterjet is key in being able to produce the component to near-net shape to enable final, fast finishing of the part on milling machines. Titanium grades cut especially well on the Bengal Waterjet.
Producing a particular medical part requiring a specific grain direction. One of Omni''s medical customers needs a cylindrical part that requires a special grain orientation from aluminum plate. The waterjet has been key in helping Omni achieve the blank having the correct grain orientation, which is then finished in a lathe operation. Waterjet made this challenging job easy because it produces a precise cut with no heat-affected zone, which would alter temper. Without it, the company would have no way to produce the part at a reasonable cost.
"Our medical industry clients require turnkey solutions that can take components and assemblies to higher levels of completion with less labor cost," says Omni president Rick Holka. "The waterjet provides us the ability to produce intricate finished components out of a variety of materials. We''re pleased with how the waterjet has contributed to our company''s success in the medical device industry and expanding into new markets. We think the results speak for themselves."