Mikron Tool (Booth 1310)
Overcoming the Machining Complexity of Personalized Implants 

 Headquartered in Switzerland, Mikron Tool supplies flexible CNC machining systems for the manufacturing of complex high-precision components and produces tungsten carbide drilling tools used in orthopedic applications. The company has developed expertise in supporting the production of patient-specific tools, addressing the growing demand for bespoke orthopedic implants.  

“Patient-specific implants are evolving from a niche innovation to a mainstream expectation in orthopedic care,” said Clive Komlenic, Head of Sales America at Mikron Tool. “Surgeons and hospitals recognize that individualized implants can reduce operating time, accelerate recovery and improve profit. But this level of personalization changes what manufacturing must deliver.”  

Komlenic explains that many OEMs are facing a “batch size 1” manufacturing challenge when producing patient-specific tools and implants, particularly when producing complex geometries from difficult-to-machine materials such as Grade 5 titanium and cobalt-chrome. Success demands flexible manufacturing cells, advanced CAD/CAM integration to convert imaging data into toolpaths, specialized tooling for abrasive alloys and stable, validated processes that ensure quality and cost efficiency.  

“Traditional machining strategies aren’t fit to that level of precision, flexibility and cost pressure,” Komlenic said. “The clinical benefits of personalization are clear, but the manufacturing world is still racing to equip itself with the tools, processes and technologies needed to produce patient-specific tools reliably and at scale.”  

Manufacturing patient-specific implants is not merely an extension of conventional implant machining, but an entirely different model.   

“The combination of exotic alloys, free-form geometries and micro-tolerances means there is no room for error,” Komlenic said. “OEMs must rethink process stability. Toolpath planning, fixturing, tool selection, coolant strategies, chip evacuation, vibration control, and surface finishing all take on new levels of complexity.”  

According to Komlenic, Mikron Tool supports the high-complexity, high-precision requirements of orthopedic manufacturing and has the capabilities to produce patient-specific instrumentation, including specialized tools for medical-grade materials, expertise in complex, free-form machining and customizable solutions.  

“Mikron Tool combines the tooling technology, application know-how and process-engineering capabilities that OEMs need to make patient-specific manufacturing both technically reliable and economically sustainable,” he said. 

Instrumental Machine and Development (Booth 1151)
Fiber Laser Cutting Technology Provides State-of-the-Art Precision  

Instrumental Machine & Development (IMD) is based in Warsaw, Indiana, and specializes in orthopedic instrumentation, sterilization trays and O.R. accessories, with comprehensive in-house capabilities that span engineering, prototyping, manufacturing and finishing. The company addresses complex manufacturing challenges by delivering precise, efficient production solutions that meet the rigorous standards of the orthopedic market. 

“With one of the few state-of-the-art laser cutting machines in our region and a wide range of in-house capabilities, from prototyping through large-scale production runs, we offer flexibility, speed and consistency,” said Jacqueline Speicher, Head of New Business Development at IMD.  

Speicher highlighted the advantages of IMD’s fiber laser cutting technology.   

“Laser cutting is especially important in orthopedics because it ensures precision, complexity and repeatability,” she said. “Implants and instruments have very tight tolerances, and laser cutting helps us achieve those tolerances with reduced risks for mistakes.”  

In addition to precision, laser cutting allows for the creation of complex features that are difficult or impossible to achieve with traditional machining methods, including micro holes, fine slots and intricate patterns. The technology also reduces tool wear compared to conventional machining, allowing for higher throughput and more efficient production.  

“Laser cutting is cutting-edge technology with accuracy down to small details,” Speicher said. “We can cut titanium and stainless steel to create instrumentation and implants.” 

Precision Associates (Booth 529)
Addressing the Growing Concern Surrounding PFAS in Medical Devices 

 Per and polyfluoroalkyl substances (PFAS) are built into countless orthopedic and medical device components. The broad class of chemicals is valued for their resistance to heat, water, oil and harsh operating environments, properties that have made them a mainstay in medical and applications in which durability, performance and chemical resistance are critical.  

However, the regulatory landscape surrounding them is tightening rapidly, according to Kyle Werremeyer, Vice President of Sales and Marketing at Precision Associates. “As PFAS come under pressure, reliable replacements must be found without sacrificing performance,” he said. “What was once viewed as a technical material discussion has now become a pressing business issue, driven by growing regulatory scrutiny in the United States and globally.”  

In some states, that urgency is even more pronounced, with reporting requirements scheduled to take effect soon. Some new regulations may result in full bans on products containing intentionally added PFAS, according to Werremeyer, who recommends that orthopedic companies research state laws to better understand evolving requirements.  

Because PFAS can be present across materials, components, coatings and manufacturing processes, these concerns extend beyond a single product or supplier.   

“It can affect entire medical device supply chains,” Werremeyer said. “The combination of regulatory pressure, evolving definitions and limited validation capacity makes early action essential. Companies that wait until they are forced to respond are far more likely to face higher costs, added risk and unnecessary disruption to production.”  

But replacing PFAS is rarely a simple substitution. The materials are typically selected for highly specific performance requirements, meaning alternatives must be carefully evaluated with engineering assessments, application testing, regulatory review and final OEM approval. That requires time, alignment and close supplier collaboration.  

“Precision Associates is positioned to help OEMs navigate this challenge because we operate where material science, manufacturing and custom application performance come together,” Werremeyer said. “We work directly with elastomers, engineered materials and critical sealing applications where PFAS has historically played an important role, especially in demanding environments where performance cannot be compromised. That gives us practical visibility into where these materials show up, where the risks are and what alternative paths may be viable.”

Ahaus Tool & Engineering (Booth 755)
Custom Automation and Workholding for Scalable Manufacturing  

Orthopedic device manufacturers face growing pressure to increase throughput, maintain tight tolerances and reduce reliance on manual labor while ensuring precision, consistency and compliance with strict regulatory standards. Ahaus Tool and Engineering offers solutions to complex manufacturing, tooling and automation equipment needs.   

“This is relevant today due to so many challenges that manufacturers face, namely labor shortages, process inefficiencies and inconsistent quality,” said Eric Partin, Northwest Sales Engineer at Ahaus.  

To Partin, seeking experienced, proven guidance is crucial in creating smooth and consistent medical device manufacturer operations.  

“In regulated environments, automation paired with validated fixturing improves traceability and process control,” he said. “Modular and flexible fixturing solutions also allow manufacturers to adapt quickly to design changes and low-to-medium production volumes that are common in medical manufacturing. Fixturing and automation increase production efficiency, enhance product quality and reduce operator dependency.” 

Maximizing productivity with repeatable fixturing and dependable automation reduces dependencies on operator adjustments and consistency in quality, according to Partin, who added that investing now in automation will pay off in the long run.  

“Many device manufacturers are deciding what the next level looks like for them,” he said. “Investing in modern, custom automation might be a step toward where your company can be in the coming years.”  

Partin highlights Ahaus’s experience as a custom, build-to-order automation solutions provider. “Our communicative, transparent project management team will see you through the entire process, giving you eyes and ears on the project until it hits your floor,” he said. 

Monnier + Zahner (Booth 960)
Automated Grinding and Polishing of Hip Implants and Medical Drills  

As endoprosthesis implants continue to improve patients’ quality of life and biomaterial technologies advance, manufacturing processes must also evolve. Monnier + Zahner highlights its M682 modular grinding and polishing machine as a solution designed to deliver enhanced control over force, time, temperature and position — the capabilities it believes enable more precise and reliable manufacturing outcomes.  

The company also features M683, a third-generation rotary transfer grinding machine for medical drills and other round tools that employs 20-plus CNC axes to index parts through five stations, each working simultaneously to grind critical features. The system increases flexibility and accommodates a wider range of drill sizes, while achieving cycle times that are one-fifth those of delivered by traditional grinding machines.   

Both machines have been designed around automation, which can be expanded to include Automated Guided Vehicles (AGV) and Autonomous Mobile Robots (AMR) for maximum autonomy.  

According to David Harroun, Vice President at Helios Gear Products (the U.S. partner of Monnier + Zahner), the machines’ high level of quality and performance is rooted in decades of Swiss manufacturing expertise. “The M682 is our latest generation of spherical grinding/polishing machines for making hip and shoulder implants in cobalt chrome or ceramic materials,” he said.  

Beyond its advanced control capabilities, Harroun points to additional benefits of the M682, including active gaging to ensure precise dimensional control and a modular platform that supports additional processes such as bore and taper grinding.  

“All of our machines use innovative automation systems developed in-house, which work seamlessly with the processes,” he added. “The systems can be further expanded to work in tandem with AMRs to transport parts from process to process.”  

Harroun said that automation is no longer optional for orthopedic manufacturers, particularly high-volume producers, and said Monnier + Zahner develops custom machines to address emerging manufacturing challenges.  

“If a machine does not exist to fulfill a current requirement, we are happy to partner with OEMs to develop a new solution,” Harroun said. “Monnier + Zahner and Helios can properly support OEMs with new technology for advanced medical manufacturing.”  

Tap into the expertise of these suppliers and hundreds more at OMTEC, June 9-11 in Chicago.