Aesculap Deburrs Bone Saws Using Ultrasound

Aesculap AG develops and manufactures medical devices and technologies for surgical procedures. To automate the deburring of its Rapid Action saw blades, the company has opted for a system from the technology specialist ultraTEC innovation GmbH. Available in the UK from VOLLMER UK, the company’s deburring technology removes unwanted burrs and fibres from metal components contact-free, using ultrasound.

“Our vision is to protect and improve people’s health worldwide,” says Manuel Welte, Process Manager Engineering & Processes at Aesculap AG. “To achieve this, we manufacture surgical instruments in a wide range of dimensions, down to the micron scale. We currently have around 28,000 products in our portfolio.”

Within micro-production, the company manufactures delicate clamping tools for micro-needles measuring approximately 70 microns in diameter – roughly the thickness of a human hair. Founded in 1867 as a small workshop for surgical instruments, Aesculap is now part of the B. Braun Group. The company, headquartered in Tuttlingen, Baden-Württemberg, has established itself as a leading global manufacturer of medical products and technologies. With around 13,000 employees, Aesculap generates annual revenue of approximately €2.3 billion.

“We consistently pursue technological openness to remain competitive. This was one of the reasons for converting the deburring of our Rapid Action saw blades from manual to automated processing,” says Manuel Welte. “We evaluated and compared various technologies. Ultimately, the ultraTEC system proved to be the most suitable solution for our specific application. ultraTEC’s solution-oriented approach, its technical expertise, as well as short distances and regional proximity were additional decisive factors.”

ultraTEC innovation GmbH, part of the Biberach-based VOLLMER Group, is based in Laupheim in Swabia. To deburr metal components, the company has developed an innovative process that uses ultrasonic energy to remove disruptive burrs and fibres. The technology is used for Rapid Action saw blades, which Aesculap manufactures from high-grade stainless steel.

These single-use saw blades feature a sharp cutting edge for precise, efficient cuts during surgical procedures, including bone or tissue incisions. Each blade is designed for single use and supplied with sterile packaging to ensure product cleanliness and safety. The blades are mounted on the battery-powered Aesculap Acculan motor system, whose titanium housing allows sterilisation with alkaline cleaning media. Rapid Action saw blades are used in operating theatres, outpatient clinics, emergency departments and other medical facilities. They are available in working lengths from 25 to 90mm and widths from 5 to 30mm.

“As burrs inevitably occur when grinding the cutting edges of the Aesculap saw blades, post-processing for deburring is essential,” says Dieter Münz, Managing Director of ultraTEC innovation GmbH. “With our A25 S ultrasonic deburring system, this process can be carried out contact-free and automatically during unmanned shifts. The result is a perfectly deburred saw blade that retains its sharp cutting edges.”

At present, up to six employees at Aesculap manually deburr the saw blades using nylon brushes, abrasive cleaners and triangular scrapers. In future, the blades will be automatically guided through a process water tank towards a high-frequency ultrasonic sonotrode using the process developed by ultraTEC. Powered by a generator, the sonotrode oscillates 20,000 times per second with an amplitude of 0.1 mm. These vibrations cause the burrs and fibres on the stainless-steel component to move back and forth until they break off, leaving sharp edges.

“ultraTEC specifically integrated the ultrasonic deburring system into our process chain, in which we transport the saw blades from raw material to finished product within a dedicated workpiece carrier,” explains Manuel Welte. “Without manual intervention, the saw blades are transferred via a pneumatic gripper system into the A25 S process tank, deburred, and then returned to the carrier.”

Up to three sonotrodes installed in the process water tank enable machining of the saw blades in a single clamping operation. The complete processing cycle for one Rapid Action saw blade takes 60 seconds, and the specially developed Aesculap workpiece carrier can accommodate up to 180 parts. The ultraTEC A25 S system processes various saw blade types with working lengths from 40 to 6mm. Following planned validation of the system, Aesculap will also be able to eliminate one of its two 100% inspection stations.

“Specifically for Aesculap, we delivered our A25 S in a special paint finish aligned with the company’s corporate design and internal colour scheme,” says Dieter Münz. “For us, Aesculap exemplifies a partnership-based collaboration in which we not only contributed our ultrasonic deburring expertise effectively but also implemented individual customer requirements.”