Fabrication at the Speed of Light: The Software Factor

Fabrication at the Speed of Light: The Software Factor

By Mike Adelstein

What we’ve got here is a failure to communicate.”

—Cool Hand Luke

This line, made famous by Paul Newman in the movie “Cool Hand Luke,” is timeless and can be applied to so many of the issues that we face today, even contract manufacturing.

Software, especially as it relates to the transfer of a drawing from a medical device developer to the contract manufacturer, is a good example of this issue.What may seem as simple as drawing a part in computer-aided design (CAD) software and sending it to a vendor for a quote, often can lead to misspecifications, inaccurate pricing, and perhaps even distorted lead times.

Typically, when a customer sends a drawing out to have parts manufactured, the files need to be converted to a machine language suitable for the fabrication process of choice. Often, however, due either to a lack of knowledge or miscommunication from both sides, this step can become time consuming. This often is because process design rules and guidelines have not been followed with respect to the drawing. Features such as corner radius and dimensional tolerances affect cutter or beam width compensation and lead-in/out control parameters that are critical to the fabricator.
 

Automated software controls for the BioFAB 1000MB laser system. Photo courtesy of Potomac Photonics.

Frequently, these need to be calculated, tested and optimized. In addition, manual manipulations of the drawing to adapt it for the fabrication process often are required before and during the manufacturing process. Sometimes, even the cut path, scale of drawing and missing dimensions need to be obtained from the customer before the final “run rate” can be determined and the proposal generated. All of these items have the potential to increase the lead-time of the project and create confusion and frustration between both sides. In this new economy where there is considerable pressure in the medical device industry to shorten the development cycle and advance products to the clinical and U.S. Food and Drug Administration approval phase, these delays can be costly and are unacceptable.

The good news is that many contract manufacturers are recognizing this issue.By communicating design rules up front and implementing custom software suites to run projects, it is possible to turn around “in-spec” first articles in record times. For example, by providing customers with process-specific design rules up front, companies are able to cut back on drawing modifications. In addition, the integration of powerful optimization routines that have the ability to calculate key manufacturing parameters has proven critical to improving part quality, increasing overall productivity and minimizing material waste. Equally important, this approach can significantly reduce or eliminate the requirement for manual drawing changes and programming.

A CNC company that we benchmarked with regard to software optimization has made this the cornerstone of its rapid prototyping strategy. The company’s software provides customers the ability to upload drawings straight to their websites. Once the drawing is uploaded, the software will evaluate and convert the information to machine-readable language within hours.The optimized drawing then is sent back to the customer for review along with an interactive quote to manufacture the part. The quote document, which allows modification of quantities, turnaround time and certain design specifications, dynamically updates pricing based on the customers input. Once the customer approves the document, the design is sent directly to a machine on the factory floor, which allows parts to be processed and shipped within as few as 24 hours.

Another trend that quickly is catching on is contract manufacturers providing their customers with free custom software that is optimized for their specific fabrication process. In these cases, the software typically is available for the users to upload from the contract manufacturer’s website. Similar to many conventional CAD programs, this software often is designed so that even non-engineers can use it. In fact, many such packages guide the user through the drawing process in real-time and have features that can offer advice or correct mistakes automatically. Standard controls, such as the ability to see and spin the part in 3-D, round or chamfer corners, create sheet metal bends and set tolerances, are all built into the software. In addition, some software packages offer a “wizard” that can design the parts based on specific entered criteria and the ability to select from many different types of materials and coatings.

Another major benefit of these programs is the faster quoting of jobs. This capability allows the software to analyze the part design, material, shape, finish, etc., in order to provide the user with an instant price. This feature can be very helpful because users can try various combinations of designs, materials and finishes in order to find the optimal price. The drawings then are uploaded back to the contract manufacturer’s website and the order can be placed. This process, which allows anyone with a computer to design and order custom parts without investing in expensive drawing software, likely will grow in popularity as more people get comfortable with the idea of designing their parts with these types of CAD packages.

Increased competition in the healthcare industry coupled with mounting pressures to reduce costs is further weighing on an already challenged medical device industry environment. Whereas several weeks to a month once were the norm for prototyping lead-times, a 24- to 48-hour turnaround time is becoming the new reality. Software improvements and upgrades clearly are one way that customers and their vendors can work together to improve communication and achieve success.

Mike Adelstein is a 13-year veteran in the laser microfabrication industry and currently serves as the senior vice president and chief operating officer of Potomac Photonics.His column, “Fabrication at the Speed of Light,” is part of series of articles he is writing that suggests how new technologies can be applied to contract manufacturing. A graduate of the University of Maryland,Baltimore County, he has a Bachelor ofScience in Biochemistry and Molecular Biology and Master of Science in TechnologyManagement. Adelstein can be reached at [email protected].