Medical Design Briefs - July 2023 - 36

Sears and his team use the Smart Teach offline and online
programming functions in the VMR software module to automatically
position and optimize the robotic arm inside the
ScanBox to achieve optimal angles for the ATOS sensor to
collect adequate data. To advance their process further, they
worked with CAPTURE 3D's team of automation experts to
create a customized template using scripting methods to perform
automated 3D scanning and inspection specific to Orchid's
customers' requirements. The script
is processed
through ATOS Kiosk Mode, which seamlessly communicates
to the GOM Software VMR module to execute batch scanning
for multi-part inspections. The operator places multiple knee
implant components, averaging 24 at a time, onto a fixture
within the ScanBox. Pressing a button activates the ATOS
ScanBox to begin digitizing the batch of parts. The software
intelligently separates the 3D mesh data sets of the multiple
components and stores each in a specified folder. The software
then loops and takes each individual data set, applies the
proper measurement inspection template, and automatically
generates a report.
By implementing this process, Orchid immediately met
the initial goal of decreasing inspection time and increasing
part information.
" One knee implant product previously took us about four
minutes a piece to inspect, and we only had four features being
measured on it using a CMM. The customer wanted us to check
a lot more features, so we added many more features than we
normally would and using our ATOS ScanBox, we still save time
- 40 pieces would take three hours to inspect just four features
on each piece with a CMM. Now it takes us about 45 minutes to
an hour for the same number of parts, and we're inspecting way
more features, " says Kirk Dorr, a quality control supervisor at Orchid
Orthopedic Solutions.
Inspection templates for any given component designate
which features will be inspected and reported. Orchid primarily
uses ATOS technology to inspect casting components with
surface profiles, such as the inside fitting surface of the femoral
component that mates with the bone. For example, an inspection
template for a stemmed tibial plate would check surface
profiles to ensure the part conforms. These geometric dimensional
profiles vary from tight profiles, like the stem of the tibial
plate, to details like the injection site in the wax state. Data
visualization also reveals whether a part needs reworking by allowing
them to check features like pocket depth between one
area and an outside rail to ensure that the part is conforming
properly. Creating inspection templates for each component
is fast and easy. Once created, the specific inspection elements
and analysis are automatically applied based on the template,
increasing efficiency further.
Multiple knee implant components in a fixture for automated 3D scanning.
An operator at Orchid Orthopedic Solutions working with the VMR module to perform
automated 3D inspection.
36
The full-field 3D data capture that ATOS provides also enables
reverse engineering. Sears and his team use ATOS to scan
the in-house tooling used to create the waxes that start the casting,
generating an STL mesh, or digital twin, representing the
actual tool after reworking. Depending on the circumstance,
they bring the data into a CAD platform and create a solid model
to provide to a tool manufacturer to recreate the tool when
needed. Some of Orchid's wax tools are 20-25 years old and
have no model available, making the ability to use ATOS to
quickly create an accurate model for reproduction a critical advantage.
Archiving the data also allows it to be retrieved for various
reasons, such as if it were damaged in production or needed
to be replaced due to wear.
Orchid's team also benefits from interacting with ATOS GOM
Software visual data to display the information more clearly, while
having the flexibility to make it as detailed or undetailed as necessary.
The ability to manipulate the data to display inspection features,
visualizations and models helps make inspection reports
that support clear customer communication and collaboration.
" The amount of flexibility we have with reporting the inspection
templates is vastly improved over CMMs. CMMs have a lot of
manual reporting that you don't really have the ability to work
with, so it's like you're at the mercy of what images you get out of
that system, and they're nowhere near as helpful as a 3D surface
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Medical Design Briefs - July 2023

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