en.Wedoany.com Reported - German medical device manufacturer Stoffel has solved micron-level precision challenges in microsurgical instrument manufacturing by introducing the BLUM (BLUM-Novotest) precision measurement system in its underground workshop in Tuttlingen. This has increased the pass rate of products such as neurosurgical micro forceps from 65% to 98% and reduced delivery time by 40%.

The cup width of biopsy forceps produced by Stoffel is only 0.8 mm, with a blade edge thickness of 0.01 mm—less than one-fifth the diameter of a human hair. The two blades must close perfectly flush. Its workshop is located in a basement without an air conditioning system. Day-night temperature differences and frequent tool changes cause thermal expansion and contraction of the machine tools, rendering traditional temperature compensation models ineffective at the micron scale. Previously, the machine tools required about 20 minutes of warm-up each day, and the first-article pass rate was nearly zero.

BLUM's Z-Pico probe features an extremely low measuring force design (0.1N), enabling safe measurement of micro tools with a diameter of 0.05 mm, with a repeatability accuracy of ±0.2 microns. Its photoelectric triggering method involves no mechanical contact, avoiding wear. The system also establishes a dynamic temperature compensation strategy: measuring key points after rough machining and calculating compensation values, superimposing tool thermal expansion data before finishing, and dynamically updating compensation coefficients through measurement of each part.

For the manufacturing of circular surgical instrument handles, BLUM provides the LaserControl Micro Compact NT laser system, which non-contact acquires Z-axis and Y-axis data simultaneously and features a built-in air blow device to clean the measurement area, avoiding past measurement errors caused by chips stuck in the reference slot.

After introducing the BLUM system, the machine tool warm-up time was reduced from 20 minutes to 2 to 3 idle runs, the first-article pass rate increased to over 95%, and overall production stability throughout the day improved significantly. Compensation values are automatically monitored by the system. When abnormal values exceed 0.04 mm, the machine tool automatically stops, preventing tool collisions and spindle damage accidents.

Taking neurosurgical micro forceps as an example, the blade edge thickness requirement is 0.01 mm with no gap when closed. After adopting Z-Pico real-time measurement and LaserControl three-dimensional calibration, the pass rate increased from 65% to 98%, and the delivery cycle was shortened by 40%. Stoffel stated that surgeons report the instruments provide consistent tactile feedback, offering reliable support for surgeries.

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