Medical technology currently stands out as a “pearl” in the German industrial landscape. It is reliably fueled by demographic shifts and a rising demand for products such as minimally invasive surgical instruments, implants, and artificial knee and hip joints. When it comes to quality, functionality, surface finish, or perfect fit, grinding processes play a vital role in the manufacturing of these products. It is therefore a timely coincidence that the GrindingHub trade fair (May 5–8) is taking place concurrently with Medtech (May 5–7) at the Stuttgart exhibition grounds this year. In the quest for greater production efficiency, close coordination along the value chain is becoming increasingly essential.
In Germany alone, the medtech sector consistently grows by around 5% annually. According to recent industry data, approximately 68% of sales are generated through exports. It is no surprise that manufacturing companies are drawn to these successes, particularly when looking to compensate for declines in other sectors. However, barriers to entry are high, primarily due to the complex requirements of the European Medical Device Regulation (MDR). Despite this, the German Machine Tool Builders’ Association (VDW), organizer of GrindingHub is focusing on medical technology as a key growth market. Most recently, current trends were discussed with customer industries at the EMO Economic Forum in Hanover last year. Key topics included high precision for complex, patient-specific devices, production flexibility for individual adjustments, and full traceability across global supply chains.
Essential Smooth Surfaces
Innovative grinding technology is especially in demand for diagnostic, surgical, and intensive care equipment, as well as implants and endoprosthetics. If diseased joints are to be restored to pain-free movement, no germs must adhere to the prosthetic surfaces. For artificial hip joint balls, experts speak of a surface finish with a roughness in the range of $Ra < 0.005\ \mu m$. To ensure painless injections, the tips of micro-injection needles—which may have a diameter of just 0.18 mm—must be ground burr-free. For metallic and bioresorbable stents, smooth-ground surfaces help reduce turbulence in blood flow.
According to estimates by the Federal Ministry of Health, there are currently around half a million different medical products. This diversity poses a challenge for grinding technology. In addition to high precision requirements, there is a wide range of materials involved, extending from titanium and cobalt-chromium to stainless steel alloys and ceramics.
Goal: A Harmonized Total System
“Our solutions are used primarily in highly demanding processes, complex shapes, high-strength, difficult-to-machine materials, and tolerances in the micron range,” explains Christoph Müller, Head of Sales at Dr. Kaiser Diamantwerkzeuge. “From precision grinding of titanium pins and bone drills to optical devices and the manufacture of dental drills, medical technology offers a broad field,” says the expert.
As a manufacturer of high-precision grinding and dressing tools, the Celle-based company also sees growing potential in the medtech sector. “In the current tension between cost pressure on one hand and increased requirements for quality, process stability, and sustainability on the other, our customers are increasingly relying on customized developments and process optimizations,” says Müller.
He notes that a harmonized total system, rather than individual components, is the key to greater efficiency. Consequently, the field of application technology is becoming increasingly important alongside the products themselves—whether through knowledge transfer in seminars, digital support via apps, or in-house testing fields and on-site process design for customers.
Continuous Research and Development
Marie-Sophie Maier, Managing Director of the grinding machine manufacturer Adelbert Haas in Trossingen, also confirms the shift toward process optimization. She currently identifies three central challenges in medical technology: the desire for higher process reliability, increasing demands for precision and reproducibility, and a growing variety of product variants. Automated or semi-automated environments are a prerequisite for this. “From our perspective, the seamless interaction of machine, software, clamping, and measurement technology is decisive,” emphasizes the Managing Director.
According to the company’s calculations, around 2.4 million knee endoprostheses are produced annually on Adelbert Haas grinding machines. The company states that investments in these machines pay off quickly due to significant setup time savings, fast programming, combined grinding and milling, and in-process dressing.
Maier emphasizes that medical technology is one of the most demanding fields of application. “We are continuously involved in application-oriented development and research projects, particularly at the interface between the grinding process, software, and measurement technology.” Besides further increasing process stability, the focus is on data-based optimization of grinding processes and the integration of closed-loop solutions. A closed-loop system allows for the seamless integration of machining and measuring machines. Software ensures that data from the machining machine is transferred directly to the measuring machine; the measurement report then returns to the machine, which automatically makes any necessary corrections.
Trend Toward Flexible Machine and Software Concepts
Looking ahead, Marie-Sophie Maier sees a clear trend: “We are experiencing increasing functional integration in medical components alongside stricter regulatory requirements.” For grinding experts, this means processes must not only be high-precision but also transparent, reproducible, and documentable. Additionally, flexible machine and software concepts are gaining importance to efficiently map new materials, complex geometries, and changing requirements.
This trend is likely to be a major topic in Stuttgart. For grinding experts, the concurrent trade fairs are a win-win. “As an exhibitor at GrindingHub we are pleased about this and hope for synergy effects with MedTech,” says Christoph Müller. Visitors, incidentally, have access to both events with a single ticket.
Author: Cornelia Gewiehs, Freelance Journalist, Rotenburg (Wümme)
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