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Lasers Etch Precise Marks on Small Titanium Devices
John Sprovieri // Chief Editor
Lasers create durable, black marks on titanium that can survive multiple sterilization cycles. Photo courtesy Christoph Miethke GmbH & Co.
Hydrocephalus is the buildup of cerebrospinal fluid in cavities called ventricles deep within the brain. Normally, this fluid flows through the ventricles and bathes the brain and spinal column. But the pressure of too much fluid can damage the brain. It can even be fatal.
Colloquially known as “water on the brain,” hydrocephalus can happen at any age, but it occurs more often among infants and adults aged 60 and older. Diagnosis involves a neurological examination and imaging tests to assess the size of the ventricles and the flow of cerebrospinal fluid. Treatment often includes surgical interventions, such as the placement of a shunt to drain excess fluid and relieve pressure on the brain.
Christoph Miethke GmbH & Co. is a pioneer in the design and manufacture of implants for treating hydrocephalus. Based in Potsdam, Germany, the company was founded in 1992 by engineer Christoph Miethke, who is still the company’s CEO. Miethke’s innovation was a drainage system comprising a cerebral ventricle catheter, a valve, and a draining catheter that runs throughout the body.
The company produces the tubes as well as the delicate valve that regulates drainage of the cerebrospinal fluid. The company’s high-tech assemblies have improved the quality of life for thousands of people.
“Hearing how much better life is for people thanks to our products is a fantastic motivation to give our very best each and every day,” says Christian Gleumes, a mechanical engineer in the R&D department at Miethke.
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Located within a historical, 19th century building, Miethke manufactures each implant individually using state-of-the-art technology.
Like all medical device manufacturers, Miethke must apply permanently legible, corrosion-resistant identification codes to its titanium valves for traceability. During marking, no foreign matter can be introduced into the assembly, so the biocompatibility of the implant is not impaired.
A technician inspects marks made on small titanium parts. Photo courtesy Trumpf
Laser marking is the only option. But, the size and shape of the valves present a challenge to laser marking systems. Few laser systems can consistently apply high-quality markings to the delicate valves, which usually have a curved surface. High-volume production only adds to the challenge.
TruMicro Mark laser systems from Trumpf met all of Miethke’s requirements. Ultrashort laser pulses are ideal for creating matte-black, corrosion-free markings on titanium, stainless steel, and other metals used in medical devices. Extreme peak pulse power changes only the surface structure of the metal. There is no material ablation. Because processing is contact-free with only a small heat-affected zone, the component does not change its shape and its metallic structure remains virtually unchanged. This retains the biocompatibility of the titanium.
“If you want to produce high-quality results, you need to purchase premium tools that can create that high quality. And that’s why we came straight to Trumpf,” says Jörg Knebel,
head of quality management at Christoph Miethke GmbH.
The Trumpf laser creates deep-black, high-contrast markings on the valves, such as the implant’s direction in the form of an arrow. These markings remain legible even under highly reflective surgery lamps.
Christoph Miethke GmbH & Co. is a pioneer in the design and manufacture of implants for treating hydrocephalus. Photo courtesy Trumpf
Due to the low heat exposure, enough free chromium remains in the surface to promote the self-healing process of the passive layer, which is why the passivation process step can be omitted. The marking is so durable that no signs of wear are visible, even if the device sterilized hundreds of times and clinically processed.
Miethke uses ultrashort laser pulses for more than marking. The laser is also used for precision cutting of the valve’s microtechnology components.
The TruMicro Mark allows flexible setting of the pulse duration to cover a wide range of applications. This includes black marking, high-quality engravings, and precise drilling and cutting. With high average power, a small focal diameter and telecentric lenses, the TruMicro Mark is well-equipped for precise and efficient processing. The laser’s highly dynamic optical Z-axis, in combination with a scanner optics unit, enables the system to mark the small, round contours of the valves and stents.
During marking, no foreign matter can be introduced into the assembly, so the biocompatibility of the implant is not impaired. Photo courtesy Trumpf
A dialog between equal partners is how Miethke summarizes its partnership with Trumpf. Engineers from Trumpf and Miethke “tinkered” in Trumpf’s Laser Application Center in Ditzingen, Germany, until they found the perfect sample part and the optimum process settings.
“Trumpf provided us with a detailed application consultation, which was crucial, since it meant the laser configuration is tailored to our needs, and we were able to build up considerable expertise,” says Christian Gleumes, facilities and engineering project leader at Christoph Miethke GmbH.
In the future, Miethke hopes to integrate data processing into its marking process. Trumpf is already offering products for this and continues to develop its technology further.
For more information on laser marking, welding and cutting technology, visit www.trumpf.com.
“A company with Ford’s scale can really influence the supply chain and business practices across our entire industry,” adds Sue Slaughter, purchasing director at Ford Motor Co. “It is so important that we not only think about how [we] can use our purchasing power to fuel our business needs, but also to advance sustainability.”
Because the automotive supply chain is extremely complex, the Guiding Principles contain expectations about business ethics, working conditions, human rights, health and safety, environmental leadership and supply chain due diligence for suppliers at all tiers. All suppliers are expected to uphold these standards and enforce them throughout their supply chain.
The Guiding Principles are based on fundamental elements of social, environmental and governance responsibility that are consistent with applicable laws and international standards created by organizations such as the United Nations.
Topics covered under the revised guidelines include the following:
Business ethics, including counterfeit parts and data protection.
Environmental issues, such as air quality, carbon neutrality, chemical management, circularity and water management.
Health and safety issues, such as personal protective equipment and workspace.
Human rights and working conditions, such as benefits, wages and working hours.
Responsible supply chain management, such as ethical sourcing of raw materials.
The BMW Group has implemented several projects in its packaging logistics unit to help the environment and conserve resources. The goal of the initiative is to work closely with suppliers to reduce carbon emissions and adhere to the principles of a circular economy.
BMW’s European assembly plants are using more recycled material in their packaging. For newly awarded contracts, the proportion of recycled material in reusable packaging for logistics purposes will almost double this year from around 20 percent to over 35 percent.
Using alternative sustainable materials, reducing single-use packaging, introducing lightweight packaging in certain areas and reducing transport volumes will also help cut carbon emissions.
BMW is monitoring the impact of individual measures via a CO2 calculator for packaging. The automaker’s overall aim is to reduce CO2 emissions in the supply chain by 20 percent per vehicle compared to 2019.
“Our re:think, re:duce, re:use, re:cycle approach is being implemented consistently in packaging logistics,” says Michael Nikolaides, head of production network and logistics at BMW Group. “We’re using innovative strategies to consistently reduce the volume of resources we use, thus reducing our carbon footprint.
“We are also doing our part to get the BMW iFACTORY up and running, with a particular focus on the ‘green’ side of things…with an emphasis on flexibility and efficiency, sustainability and digitalization,” explains Nikolaides. “It provides an answer to the challenges involved in the transformation to e-mobility and [leverages] the latest technologies to create a production process that uses minimal resources.”
According to Nikolaides, BMW is using more recycled material, such as expanded polypropylene (EPP) packaging. “Our newly developed EPP packaging already contains 25 percent recycled material,” he points out. “EPP is used in special containers, as its shape can be adapted to the components being packaged, allowing them to be transported safely.
“Around 360,000 of these containers are needed each year,” claims Nikolaides. “Using 25 percent recycled material allows us to save almost 280 tons of CO2 annually. There are plans to increase this proportion of recycled material even further, with the first pilot schemes with 100 percent recycled material currently underway. If these tests are successful, this configuration will become standard for new contracts from 2024.
“An additional 680 tons of carbon emissions savings can be made every year by using covers and so-called small load carriers with 50 percent recycled contents,” says Nikolaides. “As things stand, these measures are focused within the European markets due to the current waste management situation and available recycling infrastructure. But, we are working toward expanding to our locations in China, Mexico and the United States.”
BMW also plans to use folding large load carriers in place of traditional pallet cages made of steel. The plastic alternatives will be made from over 90 percent recycled material. They work in a similar way to the collapsible shopping crates that most people are familiar with.
When they’re empty, the carriers can be folded up, making them easier to transport. Nikolaides claims that using 15,000 of these new containers will reduce CO2 by around 3,000 tons per year.
“When it comes to packaging, the sky’s the limit,” says Nikolaides. “We’re launching pilot projects using bio-based materials to replace oil-based substances such as polyethylene and polypropylene.
“We are also investigating whether and in what ways we can use materials from recycled household appliances in our packaging,” explains Nikolaides. “In the long term, our aim is to use alternatives to raw materials across the board.”
BMW Initiative Targets Sustainable Packaging
BMW is using sustainable packaging in its assembly plants. Photo courtesy BMW Group
