siemens.com/sinumerik

Manufacturing Solutions for the Medical IndustryIn perfect form with SINUMERIK in the medical industry

Answers for industry.

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Image courtesy of DMG / MORI SEIKI

Fit at any age: Further improving the health of human beings represents a huge challenge for manufacturers of medical prod-ucts. They must produce implants and instruments that are tailored to address individual require-ments, and at the same time be affordable.

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Leading through innovative CNC technology Highly automated manufacturing processes are establishing themselves in the produc-tion of medical products – whether artificial joints, surgical instruments or dental appli-cations. The industry requirements are quite clear: implants and instruments can be pro-duced more precisely and faster with CNC technology.

The cross-discipline know-how of Siemens ensures maximum efficiency within the CAD/ CAM-CNC process chain ensuring products with the highest quality level. As a conse-quence, Siemens technology allows manu-facturing companies to manage a more flexi-ble manufacturing process – and at the same time, optimize their production. With many years of experience in CNC technology based on the SINUMERIK system, Siemens supports the customers through facilitating cost-ef-fective production of innovative medical products.

Content

Leading-edge solutions 04

CNC controls for the medical industry 06

IT integration 10

CAD/CAM-CNC process chain 12

Service and support 14

Aerospace

Power Generation

Automotive

Electronics

Medical

Siemens Machine Tool Systems – A strong partner for machine tools

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Solutions for every industry that are fit for the future

A strong partner for the machine tool environmentSINUMERIK CNC controls have been influencing the machine tool market for over 50 years. Siemens Machine Tool Systems is present in the market with the innovative force of a unique and experienced develop-ment team so that also in the future, highly productive machines can be implemented with SINUMERIK CNC con-trol systems. In addition to innovation, Siemens places the highest emphasis on quality.

Global organizationWith a closely meshed network of sales, service and train-ing locations, as well as international production facilities, Siemens Machine Tool Systems is optimally organized to globally market machine tools. Here, our own Technology and Application Centers (TACs) prove our technological expertise, and secure the ergonomics of our CNC software in practical use. Additionally, Siemens is the pioneer when it comes to sustainability and energy efficiency as Siemens Machine Tool Systems plays a leadership role when it comes to energy-efficient equipment for machine tools.

The optimum solution for every industryGlobal trends such as rapid population growth coupled with the rising demand for communication equipment is placing new demands on sectors such as aerospace, auto-motive, electronics, power generation and the medical industry. Siemens Machine Tool Systems is in direct con-tact with these users of machine tools. This ensures that SINUMERIK systems represent the optimum product fit.

Premium IT integration and servicesBeyond this, we offer leading-edge IT integration and sim-ulation solutions for optimally networking the production and IT environments. This is complemented by a sector-specific portfolio of support and services to ensure a maxi-mum degree of productivity in the production environ-ment as well as efficient service and maintenance. This is reflected in the fact that you can find SINUMERIK sector solutions around the world.

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The optimum solution for each and every application in the medical industry

An extensive range of product versions and increasing price pressure in the production of medical products

demand the highest degree of flexibility and efficiency – at the same time with the highest process reliability

and quality. We offer the optimum CNC solution for every application, irrespective of whether it involves the

production of individual solutions, as in dental medicine, or in large series production of instruments.

Dental medicine: customized, piece for pieceCrowns, bridges, prostheses and inlays – dental medicine involves the pro-duction of customized parts, which must be individually adapted to the anatomy of each and every patient. Automating these processes results in decisive advantages when compared to complex and costly manual work. 5-axis machining centers equipped with SINUMERIK controls – optimally integrated in the production environment – are used to craft prostheses that are as close as possible to the patient’s original teeth. Together with our partners, we support a completely digitized process chain – from order entry and scanning through programming the machining up to milling on high-performance machines and subsequent shipping.

Artificial joints in small series productionArtificial joints, for example, knees or hips, are generally machined in stan-dard sizes in small series production batches. In addition to perfect sur-faces, the emphasis is on short re-equipping times. CNC-controlled pre-mium machines support manufacturers of prostheses to machine the specified high-quality workpieces. SINUMERIK offers comprehensive set-ting-up functions, which allow machines to be quickly re-equipped. In pro-duction, operating functions and cycles ensure that even challenging materials can be machined with high cutting velocities and moderate feed rates. Surface quality, precision and machining speed are optimally coordi-nated and harmonized with one another so that workpieces do not have to be post-machined.

Instruments in series productionTurning-milling machines are ideal when it comes to machining complex instruments, for instance bone rasps. This means that large series can be produced with a high degree of productivity. The seamless and integrated CNC functions in the SINUMERIK CNC – as well as the standard “Look & Feel” for operating and programming with SINUMERIK Operate – facilitate maximum CNC performance and operator friendliness – also in 3-shift operation.

Image courtesy of DMG / MORI SEIKI

Entry-level machines

SINUMERIK 808D

In a class of its own – SINUMERIK CNC

Whether single-part, small or large series production of medical products – depending on the specific require-

ments, CNC SINUMERIK is available in various performance classes and models. They are all based on the same

basic technical concept with a completely standard operating philosophy. They are ideally suited to address the

requirements in the medical industry: SINUMERIK 828D and SINUMERIK 840D sl.

SINUMERIK 828D / SINUMERIK 828D BASIC – the powerhouse in the compact classSINUMERIK 828D optimally addresses standard lathes and milling machines equipped with up to 3+2 axes. It fully leverages the technical capabilities of these machines and transforms them into high-quality produc-tion units to produce a wide range of medical products. The range of applications extends from sophisticated mold making in single-part production environments up to large series production of basic instruments.

SINUMERIK 840D sl – ultimate performance in the premium classSINUMERIK 840D sl represents the absolute maximum when it comes to CNC performance and level of openness and flexibility that has not been achieved up until now. It combines the highest technological performance with SINUMERIK’s inherent operator friendliness. SINUMERIK 840D sl is supplemented by an extensive range of IT integration solutions. www.siemens.com/sinumerik

Mod

ular

ity o

f the

mac

hine

con

cept

Performance

SINUMERIK 828D / SINUMERIK 828D BASIC

Standard lathes and milling machines

SINAMICS drive systemsSIMOTICS motors

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SINUMERIK 840D sl

Premium machines

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The ideal SINUMERIK CNC for every machining technology

SINUMERIK is the universal leading-edge solution to tackle complex control tasks in all processes and techniques

when it involves producing sophisticated and demanding medical products. At the same time, Siemens sets

standards when combining various technologies to create multitasking concepts. To boost productivity even

further, SINUMERIK allows robots for loading and unloading to be simply integrated.

Solutions customized to address all technologiesEmploying preconfigured technology packages, SINUMERIK controls are the optimum solution for lathes and milling machines. Also associated multitasking concepts – e.g. turning-milling and milling-turning – can be addressed using predefined solutions. SINUMERIK also includes modu-lar system functions, allowing other standard technologies to be tackled, for instance grinding and laser machining. The Run MyRobot technology package enables dynamic work-piece and tool handling. Operation, retraction, teach-in and diagnostics can be implemented using the SINUMERIK 840D sl via the CNC operator panel, thus increasing the efficiency and flexibility of the machine tool.

SINUMERIK Operate – one operator interface for every machining technologyBased on the innovative SINUMERIK Operate operating concept, all machining technologies can be operated with a standard “look & fee”. For production facilities, this offers a high degree of flexibility when deploying machine personnel. SINUMERIK Operate is the innovative basis for multitasking concepts, today and in the future.

Turning

Handling and CNC machining using robots

Grinding

MultitaskingNibbling, waterjet cutting, laser and plasma machining

Milling

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SINUMERIK CNC performance – the machining standard

SINUMERIK CNC control systems set standards relating to every aspects of machining performance for medical

products. Whether precision and speed, reducing cycle times or increasing energy efficiency and safety –

SINUMERIK sets the pace.

Highest precisionSINUMERIK CNC and SINAMICS drives compute with high-performance 80-bit NANOFP accuracy. This eliminates rounding errors and results in an extremely high internal computational accuracy in the complete controller circuit. Feed-forward control ensures that errors are almost completely compensated – and jerk limitation reduces stress on the mechanical sys-tem when axes accelerate. Thanks to Dynamic Servo Control, SINAMICS drives offer additional position control – and as an additional feature, dis-turbance resistance for the machine control.

Maximum speedWhen machining a multitude of CNC blocks in the shortest time, for instance free-form surfaces, it is the performance of the CNC that defines the speed, and no longer the machining process. Here, SINUMERIK with Advanced Surface represents the ideal solution: Advanced Surface stands for state-of-the-art closed-loop control algorithms – such as Look Ahead and dynamic compression of linear and circular blocks in 5th degree poly-nomials (NURBS). This clearly demonstrates that, equipped with SINUMERIK, machines can be operated at their physical limits.

The shortest idle timesEspecially in large series production environments, idle times, where the machine is no longer productive, represent a critical productivity-inhibiting factor. Here, with its synchronous architecture and intelligent functions, such as “synchronized actions” and “asynchronous sub-programs”, SINUMERIK provides the optimum solution. For instance, equipment load-ing can be implemented without having to make time-consuming modifi-cations to the PLC adaptation control.

Speed control

Current control

Position control

0.00

1nm

Y

X nm

Feed

N1 N12

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Kinematic transformationsSINUMERIK CNC is in its element when it comes to handling complex machine kinematics – from classic face/peripheral surface transformation for lathes through multi-side machining in swiveled planes up to dynamic 5-axis transformation in tool and mold making. Beyond this, SINUMERIK 840D sl supports all types of special transformations up to milling with robot kinematics, and therefore paves the way for the most advanced and progressive machine tool applications.

Energy efficiency with SINUMERIK Ctrl-EnergySiemens Machine Tool Systems sets the benchmark for energy efficiency in machine tools: SINUMERIK Ctrl-Energy encompasses a wide range of high-efficiency drive/motor components, CNC/drive functions, software solu-tions and services. As a consequence, SINUMERIK Ctrl-Energy offers energy-efficient solutions over the entire lifecycle of the machine – from design to operation. For instance, users have intelligent functions at their fingertips, such as being able to analyze the energy costs associated with a workpiece. By simply pressing the key combination Ctrl + E, SINUMERIK helps save energy. www.siemens.com/sinumerik/ctrl-energy

SINUMERIK MDynamics – premium millingThe SINUMERIK MDynamics milling technology package combines state-of-the-art operator control and unique technology cycles, outstanding work-shop programming and high-quality CNC simulation – all complemented by premium motion control. Based on Advanced Surface, state-of-the-art milling machines achieve maximum machining speeds with the highest surface quality and precision. Beyond this, user-friendly technology and measuring cycles support milling at the highest level.

www.siemens.com/sinumerik-mdynamicsMachining time:

281 sMachining time:

231 s

Velo

city

IT integration: transparency in production

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Easy access to all production dataThe seamless and integrated data management provides the medical industry with some decisive advantages. This is where Product Lifecycle Management (PLM) comes into play. This involves all of the data coherently linked to a specific product. All of the steps are addressed, from order entry through design and production up to invoicing. As a consequence, all of the data relevant for the legally stipu-lated documentation can be saved with low associated costs.

High data availabilityProduction planning data is transferred to selected machines via the machine control system acting as switching hub. The production data generated there sup-plement the order data, are archived and then used as basis when calculating key production parameters.

A typical IT-business process in the production

environment starts with the generation of the

customer order in the production planning depart-

ment. A highly integrated production control simpli-

fies scheduling, accelerates the various processes

and makes them more reliable. Further, it gives

management the possibility of analyzing and optimiz-

ing their production.

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SINUMERIK Integrate – the key to IT networkingSINUMERIK Integrate perfectly integrates SINUMERIK control systems into the IT landscape of modern plants. This is achieved using a high-performance software suite. The operations-orientated part of SINUMERIK Integrate integrates the machine into the IT environment of the local production landscape. Consequentially imple-mented, a complex network of all those involved in the production is created, all the way up to production man-agement. Using SINUMERIK Integrate Manage-it! MC pro-grams and tools can be organized throughout the network.

The SINUMERIK Integrate Analyze-it! provides powerful evaluation functions for machine data that have been acquired. The condition-based maintenance, which is then possible instead of preventive maintenance, reduces machine downtimes. In addition, detailed operating state analyses can be generated, which enable weak points in production to be identified, such as insufficient overall equipment effectiveness (OEE) – or noticeable mean time between failures (MTBF).

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An integrated process chain – from the idea to the finished workpiece

Seamless CAD/CAM-CNC integration for maximum productivityThe Siemens PLM software provides all of the necessary products and well-founded know-how for the entire IT networking along the complete lifecycle of a product. Industrial applications are employed in the production of prostheses, for example. The NX CAD/CAM software tool and Teamcenter – the most widely used PLM system worldwide – represent the essential modules in this process chain.

Initially, the design data flow into the NX CAD, where a design engineer develops the workpiece model. The CAM software NX CAM uses this workpiece model as basis and is networked with the SINUMERIK control of the produc-tion system. Further, it can take into account the techno-logical capabilities of the SINUMERIK MDynamics milling technology package in the CNC program. A seamless CAD/CAM-CNC process chain is obtained from the close link between the PLM solutions and the SINUMERIK CNC tech-nology. This results in maximum productivity when pro-ducing high-quality medical products.

CAM

CAD

Manufacturing

Finished product

Image-to-implant: Production of personalized implants

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Machine tool

Hospital

Implant manufacturer

CT scan MRI scan OperatorSurgeons’ portal

Segmentation Parameter- ization

OP plan

Personalized cutting guide

Personalized implant

NX CAM

Execution in SINUMERIK Integrate

Ideal in practice: Image-to-implantIn the Siemens integrated technology project “Image-to-implant”, the complete process chain starts in the hospi-tal. Based on MRI or CT scans, personalized implants can be manufactured quickly and at a favorable price. Patient data from the hospital are initially converted into a bone model, then into an implant model and directly into the control data for the CNC machine. For instance, the CNC data is generated from a CT scan through two inter-mediate steps.

Based on this data, a personalized implant can be directly produced in one step at the milling machine using SINUMERIK. The integrated, highly automated process enormously speeds up production planning. Comparable, manual design processes would require between one and two man days of engineering work. Assuming that good patient image material is available, the image-to-implant provides the CNC data in half an hour. The costs for man-ufacturing personalized implants based on this process chain are so low that these patient-specific products rep-resent a real alternative to standard prostheses. www.siemens.com/plm/i2i

SINUMERIK 840D sl

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SINUMERIK Manufacturing Excellence – service and support at the highest level

On site with field service As a global company, Siemens Machine Tool Systems also has a global service team to provide fast and expert serv- ice, repair and maintenance around the world in more than 60 regions.

Spare parts and repairA tight-knit, flexible and responsive spare parts and repair network in more than 70 regions around the world ensures that replacement parts are quickly available – and at reasonable prices.

Technical Support (hotline) Worldwide in more than 25 regions, our hotline experts answer any questions related to SINUMERIK CNC – and naturally in the local time and the local language! www.siemens.com/industry/onlinesupport

SINUMERIK trainingSITRAIN offers professional training for operating, pro-gramming, commissioning and maintaining SINUMERIK controls in more than 30 countries. One example is our SinuTrain training software. It brings SINUMERIK Operate, including the animated machine operator panel, close to reality on the PC. This means that know-how can be sim-ply transferred from the training course into practice. Thanks to SINUMERIK Operate and the original SINUMERIK CNC kernel, all operating and programming processes can be used without any restrictions. Further, CNC programs can be executed.

Procurement Machine in use Machine retrofit

SINUMERIK Manufacturing Excellence

Basic services

Field service Spare parts Repair

Technical Support (Hotline) Training

Supplementary services

Siemens Financial Services

Manufacturing IT

Extended Machine Contracts

Spares Plus Productivity Improvement

Machine Retrofit

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Field service, spare parts, technical hotline support and

training form the basis of our service and support

portfolio. Beyond this, SINUMERIK Manufacturing

Excellence, with intelligent services, adresses every

machine tool need.

www.siemens.com/sinumerik/manufacturingexcellence

Additional services With a wide range of additional intelligent services, SINUMERIK Manufacturing Excellence increases machine productivity – from the initial design through use up to retrofit.

• Siemens Financial Services – financial solutions that perfectly fit the requirements and situation www.siemens.de/sfs

• Manufacturing IT – process optimization through the implementation of the SINUMERIK Integrate product suite

• Extended Machine Contracts – tailored service contracts• Spares Plus – preventive spare parts management• Productivity Improvement – reduces the cycle times of

your existing machines• Machine Retrofit – general overhaul of CNC machine

tools

Subject to change without prior notice Order No.: E20001-A1690-P610-X-7600 Dispostelle 06311 WÜ/48212 V1.MKHSCM.WES WS 10133.0 Printed in Germany © Siemens AG 2013

The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

Siemens AG Industry Sector Motion Control Systems P.O. Box 31 80 91050 ERLANGEN GERMANY

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