Stamping out excess costs: Medical Manufacturing

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END USER: Aragon Surgical Inc., (650) 543-3100, www.aragonsurgical.com. CHALLENGE: Reduce costs when procuring a stainless steel part for a laparoscopic surgical device. SOLUTION: A contract manufacturer that stamps some previously machined part features and machines only the critical features. SOLUTION PROVIDER: Connecticut Spring & Stamping, (860) 677-1341, www.ctspring.com

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Machining metal can achieve tighter tolerances and finer surface finishes than other metalworking processes, but that level of precision comes with a cost. Aragon Surgical Inc., a Palo Alto, Calif.-based medical device firm, discovered that fact when having a job shop machine a stainless steel jaw housing for a laparoscopic surgical device from a solid, circular workpiece. In addition to wanting to reduce its cost per part, Aragon Surgical was having problems getting a sufficient number of parts, according to Brandon Loudermilk, the company’s senior R&D engineer.

At a trade show, Aragon Surgical made initial contact with Connecticut Spring & Stamping, Farmington, Conn., and discussed stamping most of the part’s features. “Our expertise is not machining from solid stock,” said Steve Dicke, vice president of sales and marketing for CSS. “It’s taking a part that is fully machined [and instead] stamping the basic part features to reduce costs and then machining the critical features.” He noted that CSS has seven machining centers and is buying two more.

However, Loudermilk was skeptical that the stamping process was suitable. “When we started, I thought there was no way anyone could stamp this part to be perfectly round and make it function properly,” he said.

To help convince him about the viability of stamping noncritical features into flat stock before the part is rolled round, CSS presented a lock tumbler for a door lock, which has features similar to those on the jaw housing. “When I saw how they could produce that part, how round it was and how good the finish was, it made me consider stamping this part,” Loudermilk said.

Being able to stamp and machine a part provides a different manufacturing perspective, according to Lou Morelli, senior member of CSS’ engineering department.

CSS engineers then hosted several conversations and went through numerous steps to determine the most important part features and figure out how the part could be stamped to achieve the tolerance requirements. Web conferencing helped enable the two companies to interact quickly and remain on the same page. In a few weeks, the companies came to an agreement and work began on production tooling for the stamping.