Orthopaedic Implants

Acme has designed and built more turnkey robotic finishing systems for orthopaedic implants than anyone in the world, with over 100 systems installed in the U.S., South America and Europe. Robotic manipulation of the implant, combined with servo-valve-controlled abrasive belt heads (utilizing radial wheel and an assortment of polishing media), replaces labor-intensive hand finishing operations.

Media usage can be cut by 50% or more. Modular tooling allows families of parts to be finished in the same cell. Each cell can include single and multiple media heads, accomplishing one to 12 finishing operations.

Processes include:

  • Removal of the casting gate with abrasive belts
  • Grinding of the casting form with abrasive belts
  • Abrasive belt polishing
  • Cut and color buffing
  • Ultra-high color buffing
  • Removal of flash on forged hip stems with abrasive belts
  • Complete finishing: hip stem, hip ball and cup, ascetabular hip shell

Robotic Buffing Knee implants

Robotic buffing of a knee implant

 Implants finished on Acme systems include:

  • Knees (chrome cobalt, zirconium, titanium)
  • hip stems (stainless steel, titanium)
  • hip cuts and balls (chrome cobalt)
  • tibia trays (chrome cobalt)
  • bone plates and nails (stainless steel, chrome cobalt)
  • hip shells (titanium ascetabular)
G-gate-grinding-hip-implants H-robotic-knee-gate-grind-system---1a IRobotic Knee polishing
Hip Stem Gate Grinding Typical Robotic Femoral Gate Grind System Knee Femoral Polishing Operation

Cost Savings

Switching from manual to robotic automation finishing alone can give you up to six times longer media life, as a result of contact efficiency (time on the part), constant work pressure, cycle time repeatability, and part path programming capability. Flexible, automatic force control, with variable-speed spindle motors, optimizes compliance (response and reaction) of the finishing heads to suit the operation.

Off-line programming and simulation (Roboguide) speeds up the program development process and increases utilization of the robotic finishing system. Programs for complex parts and shapes are created and verified quickly.

J Knee gate grind Edit1

Knee Gate Grind Operation

Heat monitoring allows automatic process modification to reduce affects of excess heat.

Universal tooling concepts developed by Acme for knee and hip finishing reduce system design, build and operation costs. All equipment is built to RIA and CE specifications.

Unattended operation, with custom part queuing options, reduces labor content.
Maintenance time and costs are minimized with on-line diagnostics and documentation. Troubleshooting can be performed via modem and/or internet, with Ethernet host support.

Media Life Management and Control

Automatic media wear compensation software ensures consistent performance throughout the life of belts and buff wheels by adjusting cell process parameters (such as cutting rate and force) to match the performance and lifespan of the media. Media life management software can provide up to five times longer belt life than conventional methods.

K Off line programming and simulation capability

Orthopaedic Component Robotic Simulation