High-speed Non-Contact Medical Inspection of Hip Inserts and Knees with Zerotouch Metrology drives productivity

The healthcare sector constantly evolves, seeking innovative solutions to improve diagnosis, treatment, and patient outcomes; its supporting manufacturing sector continues to push the limits. One such advancement is the non-contact medical inspection of orthopedic devices like hip inserts and knee implants. Traditional methods of inspecting these devices, particularly through direct physical contact by tactile probes on coordinate measuring machines, have limitations. The introduction of advanced metrology technologies, particularly that of ZeroTouch, has revolutionized how these critical medical implants are inspected and measured, ensuring better precision, safety, and efficiency.

The Need for Precision in Orthopedic Implants

Hip inserts and knee implants are among the most commonly used medical devices in orthopedic surgery. These highly reflective, precision-machined components feature complex GD&T callouts, tight tolerances, and have hard-to-reach and probe areas. These implants are designed to replace worn-out or damaged joints, offering relief to patients suffering from conditions like osteoarthritis or hip fractures. Given their vital role in improving mobility and reducing pain, it is crucial that these implants meet high standards of quality, precision, and functionality.

The manufacturing process for these implants requires rigorous quality control to ensure integrity. Traditional methods of inspection involve manual or tactile measuring tools, which, while effective, can be time-consuming. The need for faster and non-intrusive inspection methods has led to the development of sophisticated metrology equipment, such as the Zerotouch Metrology range of manufacturing floor gauges.

A Leap Forward in Medical Inspection

Zerotouch Metrology offers an advanced, non-contact inspection system designed to provide highly accurate and precise measurements of medical implants such as hip inserts and knee prosthetics. Unlike traditional metrology machines that often require physical contact, the Zerotouch Metrology Machine utilizes state-of-the-art high precision laser technology to measure the implants without touching them, comprehensively and instantaneously.

Key Features of the Zerotouch Metrology Machine:

• High Speed Laser Scanning:  ZeroTouch utilizes high-precision laser line scanners to completely digitize the surface of the implant. This technology allows for incredibly precise measurements, capturing intricate details of the implant’s geometry in full detail, fully digitizing the piece. The Zerotouch Gauge eliminates the need for physical contact. This reduces the risk of damaging the sensitive surfaces of the implants or introducing contaminants that might affect their quality.

 

• High Accuracy and Resolution: The machine provides micrometer-level accuracy, which is essential when dealing with orthopedic implants. The laser data is able to fully digitize the work pieces, putting high-density data in tough to reach areas such as pockets and on small radii, where feature extraction can better characterize the workpiece than discrete touch probing. 

  

• Fast Automated Measurement: The process of measuring implants is automated, which ensures consistency and reduces the chances of human error. The machine can also quickly process large batches of implants, enhancing production efficiency. Individual workpieces can be loaded manually or automatically. Results take seconds, not minutes. A hip insert can be scanned in as low as 15 seconds, moving across a linear stage, and a knee insert rotated in as low as 30 seconds.
• Comprehensive Analysis and Reporting: Zerotouch provides detailed individual inspection reports for individual workpieces, as would a CMM at the end of every cycle. Industry 4.0 connectivity is provided by real-time reporting to PLC and MES systems, as well as easily accessible process trend charts with SPC, with optional email and text message alerts. Manufacturing engineers can adjust processes and determine if individual machining cells have issues or are, for example, reaching the end of a cutting tool's life.

Benefits of Non-Contact Inspection for Hip and Knee Implants

1. Enhanced Accuracy and Precision: Traditional measurement methods can introduce errors due to manual handling, environmental factors, or human limitations. With the non-contact approach offered by the Zerotouch machine, measuring the dimensions of implants, such as the length, width, and angle of knee prosthetics or the curvature of hip inserts, to ensure they match the specifications for the intended patient population. Measurements are highly repeatable and precise, and correlate well to a coordinate measuring machine, ensuring uncompromised inspection.
2. Enables In-line or 100% Inspection: Fast cycle times allow to shift from batch and audit inspection methods to 100% inspection, which can be performed on the shop floor, either manually loaded or with robot automation inside of a production cell. 
3. Reduced Risk of Damage: Since the inspection process does not involve physical contact, the risk of damaging or scratching the delicate components of the implants is significantly reduced. This is particularly important when inspecting complex or intricate parts that may be sensitive to mechanical stress or contamination.
4. Faster Turnaround Time: The automated and high-speed nature of the Zerotouch Metrology Machine allows manufacturers to perform rapid inspections as low as 15 seconds to 45 seconds, depending on the complexity of the part. Machines can be released to production sooner, increasing throughput and minimizing downtime.
5. Cost Savings: With the ability to inspect large volumes of implants in a shorter period, manufacturers can save on labor costs and reduce the likelihood of defects that might arise due to manual errors. Machines can be released to production faster as the data is more readily available and distributed to the stakeholders.. Additionally, the non-contact nature of the process can eliminate the need for costly repairs or rework associated with physical measurement techniques.
6. Regulatory Compliance and Quality Assurance: The Zerotouch Metrology Machine helps achieve and maintain manufacturing process integrity, and each part complies with strict regulatory standards by providing traceable, verifiable measurement data that can be used for documentation. This ensures that the products meet the necessary safety and quality requirements.
7. Digital Twin Capture: A high-fidelity point cloud is captured each cycle and allows for archive and review of future manufacturing and quality scenarios based upon the stored digital twin. This information can be invaluable for future data mining and understanding of manufactured products. 

Future of Non-Contact Metrology in Medical Devices

As medical technology continues to evolve, the demand for high-precision, non-contact inspection methods will only increase. The Zerotouch Metrology Machine represents a significant step forward in ensuring the quality of hip and knee implants. However, the potential applications of this technology extend far beyond just orthopedic devices.

Future developments in non-contact metrology will likely include even more sophisticated imaging techniques, artificial intelligence (AI)-powered data analysis, and integration with other manufacturing technologies for the feedback loop. As the technology continues to advance, manufacturers will be able to produce even more complex, customized, and precise implants, further improving patient outcomes and advancing the field of personalized medicine.