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Morris Group Medical Industry

MACHINES ENGINEERED TO IMPACT LIFE
MEDICAL

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SEE HOW COMPANIES IN YOUR AREA
ARE USING HAAS MACHINES TO IMPROVE LIVES

NEXXT SPINE LLC  | Haas Customer Success Story
 

“We’ve grown 30% every year since 2009,” says Nexxt President Andy Elsbury. He adds that the company produces about 800 PEEK spinal implants per year, but recent growth has been for titanium 3D-printed Matrixx implants. “That is where we are growing faster than 30%.”

For more than a decade, Nexxt has machined its Honour and Struxxure implant lines from PEEK rods and titanium blanks using Haas machining centers. The company recently added a Haas drill-tap center to machine features into its Matrixx products, and Elsbury says fast growth in that product line will likely lead to new machine purchases soon.

PEEK, titanium machining

The high percentage of Nexxt’s orders are still from the Struxxure line of anterior cervical plate system implants that must be completely machined from blanks. Nexxt Programmer Beau Riser says the company uses various Haas machining centers to machine fixed plates, variable plates, and spacers for its implants.

“These cervical plates are implanted from the front,” Riser says, pointing to his neck. “Surgeons actually move your esophagus over and then implant them, and then your esophagus goes back over the top of it. You’ve got a plate sitting on your vertebrae and your esophagus is basically sitting up against that. If those screws back out at all, any time you swallow it’s going to feel like you’ve got something in the back of your throat.”

The implants use fixed or variable plates and fixed or variable screws. Fixed plates allow the screws to only go in one direction at one spot, while variable plates allow some movement around the screw head. Different surgeries require different approaches, but most implants have a mix of fixed and variable spots, all of which need to be machined to surgical-grade tolerances.

“This one plate can be used with a fixed screw, variable screw, or both. That’s why ours is, in my opinion, the best,” Riser adds. “We have sold thousands upon thousands of these things, and we’re getting very good feedback from the doctors. It’s working well for the patients.”

Nexxt machinists can make two pieces simultaneously on their Haas CNC equipment, programmed with Mastercam software. Careful material handling policies mean PEEK parts use metal fixtures, and titanium parts use plastic ones. All pieces are machined dry (PEEK can absorb some lubricating fluids), and employees wear gloves, so the parts don’t contact human skin until they enter the patient.

“The shortest cycle time is about half an hour,” Riser explains, adding that he uses about 15 tools for each part. “I do everything in one operation. I flip it over and do the bottom. The longest one is more than two hours.”

About a year ago, Nexxt added a Haas DM-2 drill-mill vertical machining center (VMC) to increase capacity for the machined titanium implants. “I love that thing,” Riser says, praising its speed and rigidity. “It has the new Haas Next-Gen CNC control, I’m getting used to it, and I like it. We made a plate on the Haas VM-3 (mold-making VMC milling machine), and then I took the exact program, added nothing, took nothing away, put it on the Haas DM-2, and it went from 7 minutes to 5 minutes.”

ABOUT NEXXT SPINE LLC

 

✔ Haas machines: 

            (2) VM-3 Mold Machines  with T5C2 tilting 2-head 5C indexers for 5-axis milling
            (1) DM-2 Drill/Mill Center with T5C tilting 5C indexer for 5-axis milling
            (1) DT-1 Drill/Tap Center with HA5C indexer for 4-axis work

✔ Products they make on Haas machines: complex medical implants and instruments

✔ Location: Noblesville, Indiana

 

Originally appeared in Today’s Medical Developments, April 2019: http://magazine.todaysmedicaldevelopments.com/article/april-2019/medical-device-machining-peek-3d-titanium-cervical-cage-0419.aspx

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Medical

Haas Automation is dedicated to helping drive innovation in the Medical Industries


The medical industry is different; you need speed, precision, and repeatability. That’s why we’ve designed machines and options specifically for your needs. Haas is at the forefront of machine tool technology, and constantly focused on innovation. That means our powerful control features, like High-Speed Machining (HSM) and Dynamic Work Offsets/Tool Center Point Control (DWO/TCPC), will keep you on the cutting-edge, and help you stay competitive.

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Watch Haas Machines Helping People Live Better Lives


Tecomet: A Spine for Investment
People often assume that opportunity comes before action in business. But Peter Wong at Willmington, MA-based Tecomet invested in seven Haas DT-1 Drill/Tap Centers with Haas TR160Y trunnion tables – before he knew how he was going to use them. The company now has a state-of-the-art machining department, and a thriving spinal-implant business unit.
The Appasamy Group: Clearing Clouds
Appasamy makes 80 percent of the intraocular lenses used in India to treat patients with cataracts. They also make the disposable syringes used to inject the lenses into the eye, as well as an enormous range of other instruments and equipment used in eye clinics and hospitals. The company relies on Haas machines to manufacture innovative products that meet local needs, at a cost far lower than imported products.
PCML: Team Building for a Better Future
In its early days, Cambridgeshire-based Haas UK customer PCML was a subcontract machine shop offering limited services to a just a few, mostly local, customers. These days, with the help of a stable of Haas machine tools, the company is a thriving contract manufacturer of complex, precision components for high-technology growth sectors, such as medical devices, ink jet printing, and life sciences.
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The Right Machines for You


Manufacturing for the medical industry requires speed, precision, and repeatability. That’s why we’ve designed machines and options specifically for your needs.

High Speed, Small Size
Haas CM-1

CM-1

Compact CNC Vertical Mill with 12" x 10" x 12" travels

  • 20 Taper
  • 3 Axis
  • 30k RPM
  • 20 Tool Capacity
    CNY ONLY
 
Versatility and Performance
Haas ST-10Y

ST-10Y

Y-Axis CNC Lathe with 12" x 16" max capacity and 1.75" bar capacity

  • 6.5" Chuck Size
  • 1.75" Bar Capacity
  • 6k RPM
  • 15 hp Power
    CNY ONLY
 
Flexible 5-Axis
Haas VF-2TR

VF-2TR

Trunnion CNC Vertical Mill with 30" x 16" x 20" travels

  • 40 Taper
  • 5 Axis
  • 8.1k RPM
  • 30+1 Tool Capacity
    CNY ONLY
 
Speed and More Speed
Haas DT-1

DT-1

CNC Drill/Tap Center with 20" x 16" x 15.5" travels

  • 30 Taper
  • 3 Axis
  • 10k RPM
  • 20+1 Tool Capacity
    CNY ONLY
 
Small-Part Precision
Haas CL-1

CL-1

CNC Chucker Lathe with 1" bar capacity

  • 5C Nose Chuck Size
  • 1.0" Bar Capacity
  • 6k RPM
  • 5 hp Power
    CNY ONLY
 
5-Axis Versatility
Haas UMC-500

UMC-500

5-Axis CNC Vertical Machining Center with 24" x 16" x 16" travels

  • 40 Taper
  • 5 Axis
  • 8.1k RPM
  • 30+1 Tool Capacity
    CNY ONLY
 
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