In Q1 2025, Danish surgical robotics developer Robovision DK initiated a redesign of their 3rd-generation laparoscopic system. One critical component—the optical sensor ring—required precision machining for high-speed, real-time angular feedback in the robotic arm.
Key project conditions included:
– Angular feedback accuracy: ±0.01° at 200 RPM
– Functional prototype delivery: within 12 weeks
Requirement |
Material |
Hole Pattern Accuracy |
Circularity (Thin Wall) |
Anodize Thickness |
Surface Compliance |
Client Spec |
EN AW 7075-T6 (EN 10204 3.1) |
±0.02 mm |
<0.05 mm |
15–20 μm (ISO 7599 AA10) |
ISO 10993-5 + RoHS / REACH |
Industry Baseline |
6061-T6 |
±0.05 mm |
<0.10 mm |
10–15 μm |
RoHS Only |
▶ 5-Axis CNC Machining Strategy
– TCP (Tool Center Point) control with ±3 μm positional accuracy
– High-speed drilling using progressive pilot holes
– Custom vacuum fixture for finish-pass setup
– H7 reaming for tolerance-critical bores
▶ Medical-Grade Surface Treatment
Step | Parameters | Result |
Micro-blasting | White alumina 800 | Uniform matte texture Sa ≈ 1.5 μm |
Anodizing | 18°C / 60 minutes | 18.2 ± 0.3 μm black layer |
Sealing | Nickel-based duplex process | >96 hr salt spray resistance |
Metric | Specification | Result | Equipment Used |
Hole Position Tolerance | ±0.02 mm | 0.015 mm | Zeiss CONTURA G2 CMM |
Flatness (Flange Face) | <0.01 mm | 0.007 mm | Laser Interferometer |
Phase | Duration | Outcome |
DFM Optimization | 3 days | 15% weight reduction, 30% fewer setups |
Prototype Manufacturing | 12 days | 10 pcs fully inspected and finished |
Pilot Batch Production | 18 days | 30 pcs delivered for verification runs |
Production Ramp-Up | Ongoing | Q4 capacity tripling in preparation |
– Micro-feature 5-axis milling: φ0.5 mm tools, aspect ratio >15:1
– Thin-wall control: achieved 0.03 mm circularity on 0.8 mm walls
– Medical-grade finishing: RoHS, REACH, and ISO 10993-5 compliant
– Rapid prototype-to-verification support for regulatory approval process
All parts were delivered with full dimensional reports, surface finish data, and traceable packaging documentation. Process details were reviewed and approved by the client’s engineering and quality teams prior to pilot deployment.
This case study is based on an actual project and published with client permission.
Suitable for supplier capability reviews, OEM RFQs, and CE-MDR documentation support.
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