T H I N K P A R T S T H I N K T O R N O S

MEDICAL
Proven solutions in the medical sector
for over twenty years.
2 Medical
A deep knowledge of the market and its needs
enables us to develop machines and machining
processes best suited to produce the different
medical components.
Tornos offers such solutions in response
to the demands and quality requirements of
its customers.

Orthopaedy and traumatology

Area of the spine

Surgical instruments

Dentistry

Orthodontics

Cardiology

Tooling
Tornos have been pioneers in this sector for
over twenty years. By virtue of our developments
and practical expertise in the medical sector,
we are in a position to propose approaches
to machine parts up to 32 mm in diameter
on our line of single spindle and multispindles
lathes and machining centers to
produce 100x100x100 mm cubic parts.
Competition means that Medtech
manufacturers and subcontractors are under
ever-increasing pressure to reduce prices.
This must not affect zero defects which must
be enforced. Dependable and highly productive
production methods are paramount.
A challenge taken up by Tornos with its
machining solutions.
THE CHALLENGE OF THE MEDICAL INDUSTRY
Single spindle
machines
Machining
centers
Multispindle
machines
Peripherals
3 Medical
OUR TECHNOLOGY AT YOUR SERVICE
for all types of parts.
You make highly demanding products, Tornos
can offer you proven solutions within a very wide
range of parts. We are at your disposal to nd
a tailor-made solution for your manufacturing
process. Our knowhow goes from turning to
milling and every other material cutting operation
needed to produce components for the medical
industry. The objective is to complete components
without any secondary operation. We will advise
you on the best machine kinematic, machining
performance, attachments and tooling.
As far as the product is concerned, we offer
expert advice to guarantee you the best choice
in terms of kinematics, machining, equipment
and tooling performances. By virtue of our exper-
tise we have acquired in materials specic to this
eld, (e.g. stainless steel for implants, titanium,
peek, biodegradable materials, Co-Cr, ceramic,
etc.), we offer the best tools and machining con-
ditions to optimise cycle times and increase pro-
ductivity.
The manufacture and production of specic com-
ponents, of assemblies indeed, constitute a veri-
table challenge that we are ready and eager to
take on.
By virtue of their experience and expertise which
have been built up over more than twenty years
working in this sector, Tornos develops products
which meet the needs of the market, high-
performance equipment in terms of machining
and reliability, new software developments, as
well as machine features and other programming
options, CADD Compatibility, OEE Interface (0ver-
all Equipment Effectiveness), robotisation, auto-
misation in order to anticipate the needs of the
market and meet their customers expectations.
In the different sub-sections of Medtech (trauma,
spine, orthopaedics, dentistry, tooling, etc.),
requirements are not always the same.
The optimum machining method for this type of
part must therefore be selected.
Tornos is the worlds only manufacturer to offer
machining solutions dedicated to the Medtech
industry on single spindle, multispindle or machin-
ing centers. Product ranges, their technical speci-
cations and their performances are dedicated to
machining parts of mid- to high-level complexity :

Sliding headstock machines : product line

of Delta, Gamma, Micro, Sigma, DECO and
EvoDECO.

Multispindle machines with xed spindles :

product line MultiAlpha (6 and 8 spindles) and
MultiSigma.

Work from barstock Tornos FB1005 and

PB 700 milling machines, ultra precise Tornos
CU 1007 machining center for work from
barstock or blanks.
Peripherals
Advice
Services /
Support
Customised
machining Turn Key
4 Medical
OUR TECHNOLOGY AT YOUR SERVICE
for all types of parts.
Complete command of machining processes,
practical expertise built up over many years and
close collaboration with highly competent part-
ners in the Medtech sector (tooling, materials,
lubricants, peripheral equipment, etc.) enable us
to position ourselves as solutions provider on
this demanding market.
The Medtech market and sub-sections
As far as dedicated solutions are concerned, its
important to know how to design and adapt
products to the type and dimensions of the parts
to be machined. The concept of product families
and lines that we manufacture is a benet when
it comes to use by our customer base. Whether
5 Medical
its a question of kinematics or programming
tools, we always strive to standardise the use,
programming and settings of different products.
Every machining operation, whether whirling
external and internal threads, tangential thread
milling, gear hobbing, drilling deep bores at high
pressure of up to 340 bar, stamping, the realisa-
tion of complex forms by HSM milling (i.e. milling
of Torx, milling by polar coordinates), is pos-
sible on virtually all the products we offer (single
spindle and multispindle). These operations are
also possible during a counter operation (second
spindle), which very often means that machin-
ing times for each operation at the bar and in
counter operation are evenly distributed and
well-balanced which in turn improves productiv-
ity. Machining times are shortened considerably,
despite the extreme complexity of some parts.
We also base our everyday operations on this
idea of real productivity in order to remain one
step ahead of the competition and offer solutions
which are perfectly suited to each requirement.
The exible conguration of our machining cent-
ers can precisely be adapted to your needs no
matter how demanding they can be. We can,
for example, refer to the experience we have
acquired in the machining of hard ceramic with
machine elements and protections in stainless
steel (CU 1007).
A tried and tested concept
Every one of your developments undergoes a
tough validation process at every stage of the
manufacturing and industrialisation process,
whatever the level of integration envisaged for
the nal product. This process involves taking
several different parameters and their implica-
tions into account.
A TRIED AND TESTED CONCEPT
6 Medical
A SOLUTION FOR EVERY TYPE OF PART
Example : maxillofacial screws, micro screws and dental implants
Example : trauma and orthopaedic screws with complex dental
implants and abutments
Example : trauma orthopaedic and spine (mono and poly axial)
screws, nails, hip screws.

Maxillofacial screws

Humeral locking screws

Schanz screws

Guide wires

Dental implants

Dental abutments

Caps / screws

Drill / reamers

Sleeves / connectors

Bone screws

Cannulated / corticalis screws

Corticalis / malleolar screws

Humeral locking screws

Locking screws

Trocar

Connecting rods

Drill sleeves

Distraction / compression rods

Dental implants

Angled abutments

Drill / reamers

Cannulated screws

Nails

Lag / hip screws

Mono / poly axial screws

Spine hooks

Poly axial heads

Connecting rods

Tooling

Nuts
EvoDECO 10a / 10e
EvoDECO 16a / 16e
DECO 20a / 20e / 26a / 26e
7 Medical
FOR MACHINING YOUR PARTS WITHOUT
SECONDARY OPERATION
Example : screws for implants, covers, simple abutments.

Bone screws

Locking screws

Corticalis screws

Connecting rods

Nails

Nuts

Tooling
Sigma 20 / 32
Gamma 20
Delta 12 / 20 Micro 7 / 8
Example : screws for implants, covers, simple abutments.

Bone screws

Dental implants

Abutments

Tooling

Dental abutments

Caps / screws

Sleeves / connectors

Dental abutments

Caps / screws

Sleeves / connectors
8 Medical
Tornos CU 1007
Tornos FB 1005
Tornos PB 700
Example : maxillofacial plate, Dental crown prosthesis, Ceramic application.
Example : cages, angled dental abutments.
Example : brackets.

Bone plate

Maxillofacial plate

Dental crown prosthesis

Ceramic application (Zirconium)

Parts of orthodontics

Cages

Angled dental abutments

Tooling

Parts of orthodontics
A SOLUTION FOR EVERY TYPE OF PART
9 Medical
MultiSigma 8x28
Simple counter operations
MultiAlpha 8x28 / MultiAlpha 6x32
Complex counter operations
Example : orthopaedic nut, screw
Example : Poly axial head, orthopaedic nut, screw

Bone screws

Implants

Polyaxial heads (spine)

Bone screws

Implants
FOR MACHINING YOUR PARTS WITHOUT
SECONDARY OPERATION
10 Medical
SOLUTION PROVIDER
Chip conveyors
Bar-feeders
High pressure pumps
Machining and
processing
Oil and air lters
Burring
Manipulating
Pallettising
Part-feeders
Cleaning
Parts
measurements
Robotisation
11 Medical
SOLUTION PROVIDER
Every day we work on making sure you can reach
your manufacturing, productivity and machined
component quality goals.
Pressure to lower prices, ever-tighter deadlines,
small production series and numerous set ups are
the kind of challenge you face every day to stay
ahead of the competition. Tornos can offer you
the right solutions to make this happen.
Complete machining in 1 or 2 clampings

We develop tailor-made kinematic machines

which mean you can increase your productivity.

We can offer you tooling which is perfectly

suited to your product and materials.

We take care of the whole spectrum :

machine-tools-cutting liquids-materials to
optimise machining conditions.

We reduce you set up time with the use of

tool presetting systems and integrated tool
measuring.

Our complete control of the robotisation

process allows us to offer solutions tailored to
your needs and to do added value operations
(, part washing, drying, etc.) in overlap.
Turning
Thread-whirling
process
Milling Boring Stamping
Cannulated screw (trauma) in titanium 380 sec.
12 Medical
PRODUCTS PERFECTLY SUITED
TO YOUR REQUIREMENTS
Products perfectly suited to your
requirements

We are experts in complex machining

processes.

We develop software functions for machining

complex shapes.

We design equipment which is specic to your

own production requirements.

We develop specic cutting tools and other

tooling in close collaboration with partners
skilled in the eld.

We can offer peripheral equipment perfectly

suited to your needs (safety, handling, measur-
ing, operator and environmental protection).
Tornos EvoDECO 16a
13
T41
T53
T51
T42
T42
T43
T14
T24
T15
T12
T21
T31
T32
T33
T15
T13
T23
Medical
PRODUCTS PERFECTLY SUITED
TO YOUR REQUIREMENTS
Dental abutments (for implant) in titanium
Realization on Tornos EvoDECO 16a
14
Z48
Y48
S58
S18
S17
S16
S15
S14
S11
S12
S13
S48
X11
Z11
MS1 X12
Z12
X13
Z13
Z21
Z22
Z23
9.2
9.3
8
7
6
4
3
1
2
5
Medical
MACHINING SEQUENCE
Optimum productivity

We develop new machining processes on

multispindle turning machines to reach an
extremely high level of productivity.

For parts in the Medtech sector, we also

adapt multispindle products to be able to run
specic operations (e.g. thread-whirling
process, high pressure drilling, internal and
external micro-milling).

We adapt peripheral equipment (e.g. handling,

measuring, swarf processing) as well as all
other general client parameters which are key
to productivity.
Locking motor
for the barrel
Motor for rotating tools of the
counter-operations pos. 8
Counter-spindle
motor in pos. 8
Titanium
15,5 mm lg. 17,2 mm
Tornos MultiAlpha 8x28
15 Medical
MACHINING SEQUENCE
Tornos FB 1005 Milling center

Numerical B axis.

3 independent tooling systems

(steady and rotating).

Machining of PEEK.
Tornos FB 1005
16 Medical
MEDICAL APPLICATIONS
Maxillofacial, orthopaedics, trauma, hip screws
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium Steel 316 L
Steel 316 L
Steel 316 L Steel 316 L
Titanium
Steel 316 L
Steel 316 L
Titanium Steel 316 L
Titanium
Titanium
Steel 316 L Titanium Steel 316 L Steel 316 L
17 Medical
MEDICAL APPLICATIONS
Mono and poly axial spine screws
Titanium
Titanium
Steel 316 L
Titanium
Titanium
Titanium Titanium
Steel / titanium Titanium
Peek
Peek
Peek
18 Medical
MEDICAL APPLICATIONS
Tooling, components
Steel 316 L Titanium
Stainless Steel 304
Stainless Steel 304
19 Medical
MEDICAL APPLICATIONS
Implants / dental components
Titanium
Titanium
Titanium
Titanium
Stainless steel 316 L
Titanium
Titanium
Titanium
Titanium
Titanium
Stainless steel 316 L
Stainless steel 316 L
Stainless steel 316 L
Titanium
Stainless steel 316 L
Stainless steel 316 L
Titanium
Titanium Titanium Titanium
Zirconia Cobalt Chrome Titanium Titanium X5CrNiCuNb 16-4
20 Medical
MACHINING TECHNOLOGY
External thread-whirling process
(main operations and counter operations)
The machining of threads for medical and dental
implants requires an outstanding level of preci-
sion, with respect to the shape of the thread and
the nish, as well as burr-free machining.
A pioneer in this sector, Tornos is the rst com-
pany to have produced and controlled the
thread-whirling process on a sliding head turning
machine.
Why the thread-whirling process ?
Materials which prove difcult to machine, such
as titanium and stainless steel for implants,
require cutting conditions which are perfect and
adapted to the needs.
The shapes of threads used for implants are gen-
erally specic to this sector and must be totally
burr-free.
Once it has been machined, the thread needs to
be both extremely sharp and tough enough to
allow for a perfect implantation into the bone
material and which is without risk to the patient.
The thread-whirling process uses cutting speeds
which are greater than traditional thread-
ing operations. When cutting stops
in the material, the very high rota-
tional speeds mean that
the swarf and its shape are kept
under control. This way, swarf
removal is straightforward.
High pressure lubrication is used
to direct the ow of swarf.
Sharpening device
Blade holder head
Centering device
Circular blades
21
z
s
c
x
Medical
MACHINING TECHNOLOGY
Internal thread-whirling process
(main operations and counter operations)
Benets of the process

Low cutting forces due to different cutting

edges and tool rotation speeds.

Superior general quality of nish compared to

standard threading processes.

Threading in a single cut.

Threads go in and come out "whole", no

tapered threads.

Perfect swarf control (ne particles) by virtue of

adapted cutting speed and cutting lubrication
on unit (pressure 20 bar).

Tool lifetime is extended and tools can be

resharpened (regular proled blades / approx.
40-60 times possible resharpenings)

Machining technology with constant prole

cutting tools or inserts.

Cutting tools are pre-set before entering

machine and rapid assembly / disassembly of
tool holder head.

Angling of the whirling head according to the

thread helix (up to 24 degrees).

Length of thread-whirling process up to

200 mm depending on type turning machine.

No burrs outside or inside threads.

External thread-whirling process at the bar and

in counter operation in 'masked time' mode.

Internal thread-whirling at the bar and in coun-

ter operation in 'masked time' mode.
Spindle 80000 rpm
Tool 1 mm
Principle diagram for internal thread-whirling process
Internal thread-whirling tool
22 Medical
MACHINING TECHNOLOGY
Boring / drilling deep bores at high pressure 120 / 340 bar
Using a high pressure cutting liquid (up to
340 bar) for boring deep bores is often essen-
tial to guarantee cost-effective and productive
machining of different components in
the Medtech sector (chamfered screws, hip
screws, tooling, etc.).
Many implants on the market require transverse
bores. In general, the ratio between the
drilling diameter and the length to be machined
is high (drilling length up to 50-60 x
the diameter), depending on shape of part.
The high pressure systems (from 120 to
340 bars) can be adapted on most our product
line equipped with a standard interface and
the integration is possible on the entire line of
single and multispindle machines.
23 Medical
MACHINING TECHNOLOGY
Boring / drilling deep bores at high pressure 120 / 340 bar
Milling of the self tapping forms
To facilitate the implantation of the screw
into the bone mass, the implants must be self
tapping to ease the penetration.
Thanks to the use of specic attachments
and cutting tools, its possible to achieve
these operations, either in main operations
(at the bushing) or in counter operations.
The use of thread whirling process eliminate
any burrs resulting from the milling of the self
tapping features.
View of a screw about 120 mm long with the various pre-settable tools used to produce it.
24 Medical
MACHINING TECHNOLOGY
Machining Torx shapes and other specic high-speed milling applications
Medical applications occasionally require mill-
ing / drilling with extremely small-sized tools.
High-speed spindles are also key to achieving
optimum cutting parameters and the required
nishes.
High-frequency spindles enable rotation speeds
of up to 80000 rpm to be reached.
These operations can be carried out on the turn-
ing machines both as main operation and as
counter operation in 'masked time' mode.
The same high-frequency spindles are used for
internal thread-whirling operations and other
end / transverse operations which require high cut-
ting speeds.
Benets

Perfect for use with small-sized tools.

Can be adapted to suit all products in main

and counter operation.

Suitable for conned spaces.

Straightforward rotational speed setting

with potentiometer.

Cutting speed adapted for increased

productivity.

Suppression of microburrs thanks to

the high cutting speed and the use of small
cutting tools.
25 Medical
MACHINING TECHNOLOGY
Machining specic shapes with the stamping process
Some components especially for the spine,
orthopedic nails and dental implants, require
specic equipment to produce complex forms,
usually by milling.
Tornos is continually developing new options
which are suited to the needs of the customer.
Alongside this, we are also developing customer
specic macros to make the programming
of complex contours more straightforward.
Benets

Machining highly complex parts without

secondary operation.

Straightforward programming of shapes with

specic macros (automatic calculations of axis
movements and incremental program steps).

Counter operations generally carried out in

masked time mode.

Milling units are mechanically set for angular

tool positioning depending on part.
26 Medical
MACHINING TECHNOLOGY
Simultaneous 5 axis machining

Available on our machining centers CU 1007
and FB1005
5 axis machining gives you the freedom to
quickly produce complex shapes on a single
machine. It is then possible to angularly position
the part on 2 axes so to effectively drill or mill
at different angles. It is also possible to do 5 axis
interpolation for deburring operations, as well
as milling complex forms with the help of the
continuous interpolation of the machines 5 axes.
Advantages

Machining of complex shapes.

Possibility to angularly position the part.

Possibility to simultaneously interpolate

the 5 axes of the machining center. Reduces
to use of form tools.

Enables to work from barstock or blanks.

Signicant gain of time, enables to machine

complex forms in one clamping.
27 Medical
PERIPHERALS
Wide range of peripherals available depending on market needs
Fire protection systems
Co
2
extinguishing is a clean solution which
enables production to be started up again imme-
diately.
Part conveyors
These conveyors can be integrated with other
part handling systems.
Coolant cooling or heating systems
The temperature regulators maintain the cutting
uid at a constant temperature allowing for high
precision machining.
Swarf conveyors
2 swarf conveyor systems are offered.
A standard system and one with a drum type
ltration system.
6 axis robot
The integration of high performing
6 axis robot offers an unequaled
autonomy of movements.
Oil mist extractors / lters
The lters are available in three versions : mechan-
ical lters (HEPA H13), electro-static lters,
mechanical adaptations for centralized systems.
Paper ltration
Enables to get an optimal
cleanliness and increases the
life span of the cutting oil.
Stainless coolant tank (Zirconia)
Stainless coolant tank with a 30 microns cartridge
lter. Capacity : 100 liters, output : 40 l / min.
Conforms to the European CE / CEM Safety Standards
This document is based on information available at the time of publication. While every effort has been made to be accurate, the information contained herein
does not purport to cover all details or variations in hardware and software, nor to provide for every possible contingency in connection with installation, operation
and maintenance. TORNOS S.A. assumes no obligation of notice to holders of this document with respect to changes subsequently made. TORNOS S.A. makes no
representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufciency or usefulness
of the information contained herein. No warranties of merchantability nor tness for purpose shall apply.
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TORNOS S.A.
Rue Industrielle 111
CH - 2740 Moutier
Tel. +41 (0)32 494 44 44
Fax +41 (0)32 494 49 03
contact@tornos.com
www.tornos.com
TORNOS TECHNOLOGIES
DEUTSCHLAND GmbH
Karlsruher Str. 38
D - 75179 Pforzheim
Tel. +49 (0)7231 / 910 70
Fax +49 (0)7231 / 910 750
contact@tornos.de
TORNOS TECHNOLOGIES
FRANCE
Bote postale 330
St-Pierre en Faucigny
F - 74807 La Roche
s / Foron Cedex
Tel. +33 (0)4 50 038 333
Fax +33 (0)4 50 038 907
contact@tornos.fr
TORNOS TECHNOLOGIES
IBERICA
Pol. Ind. El Congost
Avda. St Julia, 206 Nave 8
E - 08403 Granollers
Tel. +34 93 846 59 43
Fax +34 93 849 66 00
commercial.tti@tornos.com
TORNOS TECHNOLOGIES
ITALIA SRL
Via Cesare Pavese 21
I - 20090 Opera / MI
Tel. +39 02 57 68 15 01
Fax +39 02 57 68 15 230
italia.contact@tornos.com
TORNOS TECHNOLOGIES
UK LTD
Tornos House
Whitwick Business Park
Coalville
UK - Leicestershire LE67 4JQ
Tel. +44 (0) 1530 513100
Fax +44 (0) 1530 814212
sales@tornos.co.uk
TORNOS TECHNOLOGIES
(Shanghai) LTD
Hui Feng Creativity Garden
Feng Yu Building, 1-2F
No. 239, Xitai Rd, Xu Hui District
CN - Shanghai 200232
Tel. +86 21 6235 1235
Fax +86 21 6235 1938
china.contact@tornos.com
TORNOS S.A. THAILAND
REPRESENTATIVE OFFICE
Flat 1B, The U.N. Residence
27/28 Sukhumvit Soi 33
Bangkok 10110
Thailand
Tel. +66 2 662 3908
Fax +66 2 662 3910
thailand.contact@tornos.com
TORNOS TECHNOLOGIES
US CORPORATION
840 Parkview Boulevard
US - Lombard, IL 60148
Tel. +1 630 812 2040
Fax +1 630 812 2039
info-us@tornos.com
www.tornos.us
TORNOS BEIJING OFFICE
Rm.1706, Tower A
Dongyu Ofce Building
Jia #1 Shuguang Xili
Chaoyang District
CN - Beijing 100028
Tel. +86 10 5979 8583
Fax +86 10 5822 0483
beijing.contact@tornos.com
TORNOS TECHNOLOGIES
ASIA LTD
Unit 4, Ground Floor, Transport City
Building
1-7 Shing Wan Road
Tai Wai, Shatin
N.T., Hong Kong
Tel. +852 2691 2633
Fax +852 2691 2133
asiapacic.contact@tornos.com
TORNOS TECHNOLOGIES ASIA LTD
MALAYSIA
REPRESENTATIVE OFFICE
K-7-1, Lorong Bayan Indah Dua,
Bay Avenue, 11900 Pulau Pinang,
Penang, Malaysia
Tel. +6 04 642 6562 / 642 6563
Fax +6 04 642 6561
malaysia.contact@tornos.com
TORNOS TECHNOLOGIES
POLAND Sp. z o.o.
Ul. Brukselska 44 lok. 21A
PL - 03-973 Warszawa
Poland
Tel. +48 226 72 91 81
Fax +48 226 16 55 81
poland.contact@tornos.com
TORNOS DO BRASIL, Ltda
Av. Dr. Cardoso de Melo,
1470 Conj. 604
BR - 04548-004 Vila Olmpia
So Paulo - Brasil
Tel. +55 11 3045 6695
brazil.contact@tornos.com