High-Tech Solution for Medical Technology
In medical technology, precision is essential. Even the smallest error can have far-reaching consequences for patients and users. All the more impressive, then, is a current project that demonstrates how innovation and engineering expertise can successfully overcome even the most extreme challenges.
The Project
The process described here is a sub-process within a highly specialized automation system. The goal was to solve a seemingly impossible task: A sleeve with a diameter of only 0.35 mm had to be precisely applied to a 0.3 mm thin stainless steel wire – with a maximum deviation of just 0.003 mm – a value that marks the limits of what is feasible in industry. For comparison: A human hair is about ten times thicker than the distance between the wire and the sleeve.
This complex task was performed manually for many years, with each step requiring the utmost precision and care. The long history of manual production demonstrated the exceptional craftsmanship required to realize such a delicate and highly specialized solution. Only through the development of the automation system could production be raised to a new level of efficiency that reliably and reproducibly meets these exact tolerances.This wire will later be used in sensitive medical applications, such as in the operating room. The requirements therefore went far beyond mere functionality: It was about process reliability at the highest level, about absolute purity, and about consistent quality that allowed no deviations whatsoever. Any inaccuracy could have had serious consequences in later use.
Several special-purpose machine manufacturers had already deemed the project technically unfeasible and rejected it in advance. The scope seemed too limited, the demands on mechanics and measurement technology too high. But for the M.A.i team, this very challenge was an incentive and motivation. With a combination of engineering expertise, creativity, and practical development work, they tackled the task for which no existing solutions existed. Handling such delicate components requires a deep understanding of material properties and manufacturing processes. Even the slightest vibrations, temperature fluctuations, or deviations in geometry can have significant effects. Therefore, it was necessary not only to develop a precise automated solution, but also a system that operates reliably and reproducibly over the long term. Development in the test laboratory thus began with numerous tests, simulations, and design variations. Step by step, a concept emerged that successfully bridged the gap between high-precision technology and reliable implementation.
The Solution
Following intensive development work in our in-house test laboratory, a highly specialized automation system was created that meets the stringent requirements. At the heart of the system is a precise three-axis gantry whose movements can be controlled with micrometer precision. The system is complemented by a 2D line profile scanner with a resolution of 12.5 micrometers, ensuring continuous quality control throughout the entire process.The sleeve can be applied to the wire reliably, evenly, and with process reliability – a technical masterpiece that significantly increases both efficiency and safety.
