Milling-to-turning conversion saves orthopedic implant manufacturer 90% in tooling costs.
Download Milling To Turning Conversion
Ferguson Industrial cutting tool specialists led a full transition to CNC turning for a multinational orthopedic implant manufacturer,
What negative impacts did legacy milling cause when producing hardened steel punch dies for hip implants?
Due to the hip implant’s round geometry, the legacy milling required 7- to 8-hour cycle times, high tooling costs, and constrained machine capacity. This process consumed over 60 machine hours monthly and limited tool shop capacity.
How did Ferguson Industrial reduce the orthopedic implant production time by 87%?
Our dedicated cutting tool specialist led a full transition to CNC turning. By coordinating process engineering, tooling selection, and supplier support, we delivered a complete, production-ready solution tailored to hardened materials with high tolerances and repeatability requirements.
What steps did our cutting tool specialists take to design and implement a new turning-based workflow?
- Evaluated part geometry, material, and production needs
- Programmed CNC for 21 punch die variations
- Reviewed work holding and fixturing for the various dies
- Performed process validation and prove-out on a CNC lathe
- Integrated optimized CBN insert geometry and coating technology for H13 steel
- Provided operator training for consistent execution
What benefits can Ferguson Industrial bring to orthopedic manufacturing customers?
Ferguson Industrial provides fully integrated, turnkey support that helps manufacturing customers streamline processes, reduce expenses, and increase safety. Our expertise in machining hard materials brought this customer significant benefits, including:
- 87 percent reduction in cycle time (7.5 hours to 1 hour per die)
- More than 90 percent reduction in tooling cost (from $355 to about $31 per die)
- More than $80,000 in annual savings realized associated with reduced cycle time and tooling cost
- Increased machine capacity and shop productivity resulting in less overtime labor expense and increased scheduling flexibility
- Simplified tooling inventory through supplier and product consolidation
Ferguson Industrial delivers more than tooling — we provide end-to-end process ownership, technical expertise, and coordinated supplier support. Our scalable and repeatable results reduce manufacturing costs, improve efficiency, and increase capacity for higher-value work. Contact us today to discuss potential savings.
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