Development of a directly-driven thread whirling unit with advanced tool materials for mass-production of implantable medical parts

Medical screws are a common mass-produced implantable medical component made of Titanium. To machine the threads of these types of components, thread whirling with carbide tools is typically used. However, tool wear and low cutting speed limit the productivity and increase the manufacturing cost of such medical parts. In this study, a direct motor driven thread whirling unit for an advanced Swiss-type CNC lathe was developed and it was used with advanced tool materials such as low binder content Cubic boron nitride (CBN) and Polycrystalline diamond (PCD) to find a cost-effective and more productive alternative to carbide tools.