End-to-End Digital Manufacturing of Femoral Implants with Kaizen PLM, Seco Tools, and Additure/Nikon SLM Solutions

The Challenge

Traditional methods of femoral implant manufacturing can be complex, requiring multiple software solutions and significant manual intervention. Kaizen aimed to showcase a seamless workflow where all design, manufacturing, and simulation tasks could be completed within a single ecosystem using Siemens NX and Simcenter 3D.

The Solution

Kaizen PLM, in collaboration with Seco Tools and Additure/Nikon SLM Solutions, developed a fully digital workflow for femoral implant production. The key stages included:

• Designing the Femoral Implant: Kaizen used Siemens NX to create a detailed femoral implant model, incorporating intricate features and lattice structures to enhance osseointegration and reduce implant weight.

• Advanced CNC Machining with Barrel Milling: Using Siemens NX CAM and Seco Tools' advanced barrel milling strategy, the surface of the implant was precision-machined, achieving high-quality finishes and reducing machining time compared to traditional ball-end milling.

• Additive Manufacturing Preparation: The implant design was prepared for 3D metal printing using Siemens NX Additive Build Prep, ensuring optimal orientation, support structures, and process parameters for Nikon SLM Solutions’ additive manufacturing process.

• Simulation and Validation: Using Simcenter 3D, Kaizen simulated the implant’s structural integrity, heat distribution, and mechanical performance, ensuring compliance with medical industry standards before production.

Benefits of the Integrated Workflow

• Seamless End-to-End Process: By utilizing Siemens NX and Simcenter 3D, all design, manufacturing, and simulation tasks were completed within a single platform, eliminating the need for multiple disconnected software tools.

• Enhanced Implant Performance with Lattice Structures: The use of lattice structures in the implant design allowed for improved bone integration, reduced material usage, and optimized mechanical properties.

• Efficiency Gains with Barrel Milling: Barrel milling provided a more efficient machining strategy, reducing tool wear, improving surface finish, and decreasing cycle times.

• Optimised Additive Manufacturing: Siemens NX Additive Build Prep ensured accurate and reliable build preparation, reducing trial-and-error iterations and improving the overall quality of the printed implant.

• Improved Accuracy and Reliability through Simulation: The use of Simcenter 3D enabled predictive analysis of the implant’s performance, minimizing risks and ensuring high precision before actual production.

Conclusion

Kaizen PLM’s expertise in additive manufacturing and the medical device sector, combined with the advanced tools from Seco Tools and Additure/Nikon SLM Solutions, has demonstrated a revolutionary approach to femoral implant manufacturing. By integrating design, CNC machining, additive manufacturing, and simulation into a single digital workflow, Kaizen has set a new benchmark for efficiency and innovation in the medical industry.

For a visual demonstration of this workflow, watch the video below: