Mission-critical industries like aerospace and medtech are essential to our daily lives and often rely on components made of remarkable yet difficult-to-manipulate materials. These materials can withstand the incredible G force in flight and allow for safe placement and optimal functionality inside the human body. For example, nitinol is a member of a group of alloys called shape-memory alloys (SMAs). They can “remember” their original shape and return to it after being deformed, making them invaluable in medical devices such as stents and orthodontic wires. Similarly, trabecular metal (TM) is a biomedical material that enables osseointegration, or bone ingrowth with a metal implant, making it ideal for orthopedics and joint replacement.
However, working with these materials can present challenges, requiring specialized project management approaches and handling to achieve the desired outcomes. In this post, we’ll explore the unique challenges that can arise during manufacturing and provide practical project management tips to help you confidently oversee these projects. So, let’s dive in and discover how to succeed when managing a project with these extraordinary – and tricky – materials.
The Challenges with Difficult Materials
Working with materials such as titanium, TM, nitinol, and other difficult-to-manipulate alloys presents unique challenges that can impact the manufacturing process and project outcomes. Some of these challenges include:
- Tool wear and breakage
- Heat generation
- Uneven surface finish
- Machining difficulties
- Material waste
Overcoming these challenges requires specialized knowledge and tools. In the next section, we’ll provide practical project management tips to help you succeed when working with these difficult materials.
Project Management Tips for Difficult Materials
If you’re managing an ultra-precision manufacturing project with rare or tricky materials, consider the following hints to increase the odds of success:
Check the manufacturer’s material portfolio.
Not all manufacturers have the expertise and experience to work with difficult materials such as titanium or TM, making it essential to choose the right partner. A manufacturer with experience working with these materials can provide you with valuable insights into design optimization and the best manufacturing processes and equipment to achieve your goals.
Collaborate with the manufacturer on the design.
Collaborating with the manufacturer from the design stage using design for manufacturing (DFM), design for assembly (DFA), and rapid prototyping is crucial to ensure a successful outcome for challenging material projects. Early collaboration can identify potential manufacturing challenges and limitations from the material’s unique properties, enabling you to resolve manufacturing feasibility uncertainties before your project hits the production floor. This collaboration can also identify potential cost-saving measures, such as design modifications to reduce material waste, decrease manufacturing time, and minimize tool wear.
Confirm access to the right cutting tools.
The proper cutting tools are essential for manufacturing success, particularly when working with challenging materials. Selecting the appropriate cutting tools is critical for reducing tool wear and breakage, minimizing heat generation, and achieving a high-quality surface finish. Partnering with an expert in selecting the right cutting tools for the specific material and operation helps maximize efficiency and ensures project success.
Assess the manufacturer’s machining techniques.
Choosing a manufacturer skilled in precision machining techniques, such as optimizing cutting speed and feed rate based on material properties, can ensure efficient removal without excessive heat or tool wear. High cutting speeds can cause material deformation and poor surface finish, while low speeds can result in poor material removal rates and longer machining times. A skilled manufacturer can strike a balance between the two. Qualified manufacturers also prioritize tool condition monitoring and prompt replacement to minimize project risks.
Streamline your supply chain.
Collaborating with a single-source manufacturer can simplify your supply chain and streamline your manufacturing process when working on challenging material projects. By eliminating the need to transfer parts between multiple suppliers, you enhance accountability, accuracy, and design optimization and enjoy a smoother quality control process.
It’s true: Managing manufacturing projects involving rare or difficult-to-manipulate materials can be challenging. However, by choosing a qualified and innovative ultra-precision manufacturer and following the hints in this article, you can overcome these challenges and ensure project success. Head to our blog for more project management tips that can help you keep your manufacturing project on track.
We’ve Mastered Difficult Materials
With experience working with hundreds of alloys – including exotic and difficult-to-machine materials – we bring the technical expertise many other shops lack. Browse our extensive list of materials on our website, or contact our team to learn how we can help solve your medtech, aerospace, defense, space exploration, and other manufacturing challenges.
