Powering Arthroscopic Shaver Manufacturing From Start to Finish
Arthroscopic shavers demand tight tolerances, exceptional cutting performance, and consistent quality across high-volume production. Achieving these requirements relies on a combination of precision abrasive and grinding technologies, each contributing unique capabilities throughout the manufacturing process.
From centerless grinding and electrochemical grinding (ECG) to micro-abrasive blasting, manufacturers often employ multiple complementary processes to produce the complex geometries, sharp cutting features, surface finishes, and edge conditions required for arthroscopic blades and burrs.
Arthroscopic Shavers
Rather than functioning as standalone operations, these technologies are often integrated into a comprehensive manufacturing workflow, with each process contributing to distinct capabilities:
- Centerless Grinding establishes critical diameters and concentricity;
- ECG enables burr-free machining of complex features while preserving material integrity; and
- MicroBlasting provides precise surface conditioning, edge refinement, and finishing capabilities.
The following Case Studies highlight how these technologies work together to help manufacturers meet the demanding quality, performance, and production requirements of arthroscopic components.
Challenge #1: To Grind Two Mating Metal Components to Tight Tolerances
The foundation of an arthroscopic shaver is a pair of bull-nosed tubes, with the inner tube precisely nested within the outer tube. Both components must be ground to tight tolerances—typically within 0.0005″—to ensure smooth rotation while minimizing the potential for debris to enter the interface. The tips of the tubes typically have a rounded guiding surface, and the outer tube has a window cut into it to expose the sharp edges of the inner tube.
Recommended Approach: Glebar GT-610 Thrufeed Grinder & P4200 Profile Gauging System
For the outer sleeve, the OD of the blank tubes is precision ground using the Glebar GT-610 Thrufeed Grinder, achieving a surface finish of 3–6 RMS while consistently maintaining a Cpk of 2.0–3.0 on the outside diameter. The process removes 0.005″ of material and reliably holds a tolerance of ±0.0005″ within a fully automated, turnkey manufacturing process.
Glebar GT-610 Thrufeed Grinder: Learn More
To infeed the shape of the inner tube, the Glebar GT-610-CNC is also utilized to maintain tip tolerances of ±0.0002″. This process drastically reduces scrap rates and is designed for high-volume production via:
- A patented movable work rest blade precisely positions the tube radius for accurate, repeatable grinding.
- Integrated automation, including a Fanuc robot and step feeder, that measures each part and automatically adjusts the process to reduce scrap and support high-volume production.
For quality control, the Glebar P4200 Profile Gauging System measures critical dimensions, including radius geometry, and provides real-time feedback to the GT-610 for automatic wheel dress and size compensation. This closed-loop process ensures consistent part quality, process stability, and reduced scrap rates.
Glebar P4200 Profile Gauging System: Learn More
Challenge #2: To Efficiently Cut Arthroscopic Shaver Teeth
Manufacturers producing arthroscopic shaver teeth must achieve tight tolerances, burr-free cutting edges, and exceptional surface quality without introducing heat-affected zones, recast layers, or metallurgical changes. Conventional machining methods can generate thermal damage and increase overall manufacturing complexity.
Arthroscopic Shaver Teeth
Recommended Approach: Tridex SG-1645 Electrochemical (ECG) N/C Surface Grinder
The Tridex SG-1645 Electrochemical Grinding (ECG) N/C Surface Grinder produces burr-free cuts while maintaining tight tolerances and eliminating heat-related metallurgical damage. By combining an abrasive wheel, DC voltage, and electrolyte, ECG removes material through electrochemical dissolution and mechanical grinding, unlike EDM or laser processes that can alter material properties.
Curved shaver teeth are ground individually, while straight-cut teeth can be stacked up to 30 high with cycle times of approximately 10 seconds per part. CNC controls, precision components, and an optional pallet loader maximize accuracy, repeatability, and throughput.
Tridex SG-1645 ECG N/C Surface Grinder: Learn More
ECG achieves full-depth, burr-free cuts in a single pass with no heat-affected zone, recast layer, or work hardening. Minimal wheel wear reduces dressing frequency and can extend wheel life by up to 20× compared to conventional grinding.
Alternative Approach: MicroBlasting as a Secondary Process to EDM or Laser Cutting with Comco AccuFlo AF10
Challenge #3: To Texture the Hub to Improve Adhesion to the Overmold
If the shavers are installed in a polymer hub, MicroBlasting may also be used to engineer a surface finish to promote and optimally bond between the stainless and polymer materials.
Comco AccuFlo with ProCenterPlus: Learn More
Recommended Approach: Comco AccuFlo AF10 Blaster Equipped with Ring Nozzle (ProCenter Plus)
A textured surface finish increases the pull strength of the bond. MicroBlasting with a sharp cutting abrasive, like aluminum oxide, efficiently textures the surface. Blasting properties can be controlled to match the specific surface requirements to best bond with a hub.
Work with our Engineers to Develop the Optimal Manufacturing Solution
Whether you’re developing a complete process or addressing a specific manufacturing challenge, our engineers are ready to help. We understand that no two applications are alike, which is why we work closely with you to identify the solution best suited to your unique requirements.
Simply click the “Learn More” button below to get in touch with us.
Medical Manufacturing Technologies (MMT) is a vertically integrated business serving the medical device manufacturing industry and beyond. The company offers process development, applications and equipment, technical solutions, and aftermarket support. MMT brands include Cathtip, Comco, Engineering by Design, FEPeeler, GenX Medical, Glebar, Innova, Interface Catheter Solutions, MMT Automation, MPT Europe, R&D Engineering, SYNEO, Somex Automation, and Tridex Technologies.
