Case Study in Custom Machine Building: Spring Assembly for Medical Device Manufacturing

At KT Tech, Inc., we help customers break through bottlenecks with our custom machine building services. Our automated solutions allow you to replace manual steps, increase throughput, and streamline operations.  

Every machine we create is designed to meet a customer’s unique needs in a way no off-the-shelf solution could. No matter how specific to your operations your problem is, we can help you find a solution. 

To show how custom automation machines can transform production, this case study explores our collaboration with a medical device manufacturer. Learn how we designed and built a solution that helped them scale easily from prototype to production.

The Challenge: Manual Assembly Slowing Production

We were first approached by this longtime customer during the research and development phase of their device. We’d provided precision medical machining for the company for many years, and they were intrigued when they learned about our machine building services.

Their R&D engineers were using pliers to insert nitinol springs into a new product during prototype manufacturing. This step required a delicate touch; with this medical device, they could not risk any scraping between parts, as this could generate particulate matter that might ultimately reach the bloodstream. 

As the team looked ahead to production, they saw that spring assembly would become a bottleneck. They considered building a fixture to simplify the process, but didn’t think it would deliver the improvements they needed. That’s when they reached out to KT Tech for a better solution.

The Solution: A Custom Machine and a Hands-Off Process

We developed a custom spring assembly machine that automates the delicate process. The system delivers fast, repeatable results while protecting the sensitive parts involved. Key benefits of the machine include:

Turnkey Process

Our customer wanted a hands-off process, and we delivered. From concept development to manufacturing and training, our team handled the process. They freed up internal resources to focus on other priorities and never had to involve other partners in the process.

Increased Speed and Throughput

The original manual process took approximately two minutes per spring. Our machine reduced that to about 15 seconds, including the handling of loading and unloading. And with ongoing refinements, the process continues to get faster. 

Improved Repeatability and Quality

This automated machine eliminates variation between operators, ensuring consistent, high-quality results. It minimizes scrap and reduces the risk of introducing defects into the device.

Simple Record-Keeping and Documentation

In heavily regulated industries like medical devices, documentation is essential during the manufacturing process. Our machine has a built-in record-keeping function that logs process parameters. This data can be easily extracted into a spreadsheet for compliance purposes.

The Outcome: Streamlined Process, Satisfied Customer, Interested Coworkers

Our customer has been thrilled with the results, and word apparently spread quickly in their building. Other departments within the company have now approached us to solve their own production challenges. That kind of internal referral is the ultimate compliment, and we’re proud to be a trusted partner.

This is just one example of tailored automation, but we’re capable of building solutions for nearly any production challenge. If you’re facing a bottleneck, contact us today to discuss how we can help build an automated solution in our California machine shop!