Jossi Orthopaedics keeps 'Open Mind' about CAM Package

Jossi Orthopaedics of Switzerland has selected a CAM package (hyperMILL) from Open Mind Technologies.

Jossi Orthopaedics AG, a manufacturer of orthopaedic implants, delivers work pieces that are in demand all over the world. The hyperMILL CAM package from Open Mind Technologies plays a critical role in the development to production process at Jossi Orthopaedics.

Dr. Martin Schmidt said: “We define ourselves as a pure supplier. The products always carry our customers’ name, and they are all well-known orthopaedic companies.” The Swiss specialist works according to customer specifications, yet continuously offers new manufacturing technologies and solutions.

Schmidt said: “Our comprehensive expertise, command of the processes and use of the latest tools allow us to undercut competitors by a factor of three when it comes to the production time of parts and hyperMILL contributes to this.”

The hyperMILL allows users to program any type of machining – 2D, 3D, HSC and 5-axis milling, as well as mill/turning – from within a standardised user interface. There are hardly any modern components that require only one type of machining and this was particularly appealing to Jossi.

Jossi Orthopaedics also uses a range of machining strategies including turn-mill centres from Mori Seiki and a large number of machining centres from Hurco and Hermle to machine implants and tools. In order to find the best-possible CAM system for their programming needs, it was necessary to undertake a selection process that also reviewed two other CAM systems under consideration.

Midhat Dedovic, Head of Multi-Axis Manufacturing at Jossi Orthopaedics, said: “hyperMILL came out on top in the end, as it provides simple and efficient operation during 5axis programming.”

There are now two hyperMILL workstations in use for manufacturing and another one is used to train apprentices. 

Dedovic explained: “When it comes to the two production workstations, we use everything the system has to offer, apart from the special applications.” This results in a solution that the machines can exploit for every type of part, thus contributing to short manufacturing times.

Jossi uses the tool database contained in the CAM software as much as possible. It makes it possible to completely import tools, define individual tools and custom-assemble complete tools including holders. In addition to the material-specific cutting data, users can also create various profiles for each tool defined in the database. This way, different applications can be pre-defined and then selected in the job steps – even for the same workpiece and cutting materials.

To simulate the CAM programs, Dedovic and his colleagues stored the Machine models in the CAM system. This way, it is possible to check the programs created, either in terms of the toolpaths created or in terms of complete workspace and machine monitoring.

Dedovic said: “We alternate in this respect. For 5axis programs, we perform collision checks directly during programming. For 2D paths, the check is performed at the end as part of the complete simulation."

The CAM experts use existing simplification and acceleration options by copying jobs or the entire job list. There are five sizes for the components for knee joints, for example. When it comes to the job, Size 4 is identical to Size 5. Here, copying the job list helps the user to progress quickly.

Dedovic explained: “We also use automatic feature recognition to speed things up.” Automatic feature recognition detects geometries from solids and surface models, such as holes, stepped holes with and without threads, as well as open and closed pockets. Parameters are automatically generated that are required for the programming of machining strategies and for tool selection. Jossi Orthopaedics uses this advantage when it comes to inserting holes on free-form surfaces that can be placed anywhere.

The experience that Jossi Orthopeadics has had with hyperMILL and Open Mind has been very positive.

Dedovic concludes: “I’m fully satisfied with the product, so much so that I can say that I don’t want to use any other CAM system. We are also delighted with the support provided by Open Mind, both from Switzerland and the head office in Germany - its excellent.”