Case Study: Leading Medical Device Company achieves consistent, medical‑grade deburring and higher throughput with Proto3000

Deburring Ultrasonic Bone Cutting Saws For Medical Device Industry

Leading Medical Device Company, an EU manufacturer of high‑value surgical instruments, faced inconsistent, time‑consuming manual deburring of milled ultrasonic bone‑cutting saws that risked trapped debris, bacterial growth, corrosion and high scrap rates. They engaged Proto3000 to identify a cost‑effective, environmentally friendly automated finishing solution to improve cleanability, preserve sharp edges and reduce lead times.

Proto3000 implemented a DryLyte solution using a DLyte 100PRO with custom fixtures and optimized dry‑media electropolishing cycles, achieving a single‑step 4‑minute process for 16 pieces (5 minutes including load/unload), 0.01 g material removal per part, and capacity up to 1,200 parts/day (300,000/yr). Proto3000’s system delivered homogeneous, biocompatible, corrosion‑resistant finishes that preserve tolerances and sharpness, cut processing time by ~85% and costs by >80%, reduced scrap and worker exposure, and yielded OPEX ≈ €0.20/part and CAPEX ≈ €0.50/part over five years.