Medical Device & Orthopedics · Implant machining

A new standard in medical machining

Bone screws, pedicle screws, and trauma hardware live or die on one feature: the hexalobular socket (TORX®). Cut it in titanium, stainless, or cobalt–chrome and it work-hardens, burrs, and eats tools. We bring Mikron Tool's Hexalobe family — a combined drill and a micro endmill that machine the socket about 50% faster, near burr-free, with a chrome-free coating built for implants — plus the application specialists to prove the cycle time on your machine.

Mikron Tool · Hexalobe TORX® Mikron Tool Hexalobe tools machining a hexalobular TORX socket in a titanium medical bone screw
50%
faster socket machining vs. conventional milling (up to 50–60% in DMG MORI trials)
432
operations → steps → tools — one turnkey strategy
Ra 0.2µm
socket surface finish, near burr-free (Rz 0.8 µm)
T4–T30
full hexalobular range · ø0.2–3.8 mm to ISO 10664

The Hexalobe strategy: two tools, three steps

Four operations — drilling, chamfering, milling, deburring — collapsed into three steps with just two tools. The combined drill does double duty: it opens the bore and chamfer up front, then comes back to deburr.

Step 01 · Drill
Bore + 120° chamfer
CrazyDrill Hexalobe
Center bore and a 120° chamfer in a single plunge — 140° tip, or 180° flat where the design needs it. Ra 0.2 µm straight off the drill.
Step 02 · Mill
Cut the lobes
CrazyMill Hexalobe
The micro endmill cuts the hexalobular profile by vibration-free helical interpolation (pitch up to 0.8×d) or side milling. CoCr and stainless get a lobe pre-drill first.
Step 03 · Deburr
Re-chamfer clean
CrazyDrill Hexalobe
The combined drill returns for a light re-chamfer, leaving a nearly burr-free socket — and cutting out the secondary hand-finishing that usually follows.
CrazyDrill · Micro-drilling titanium

Drilling titanium at micro scale — deep, fast, in control

Titanium fights back with heat and stringy chips that pack a small hole and snap micro-drills. Mikron's CrazyDrill family answers with coolant delivered right to the cutting edge, an entry and flute geometry tuned to clear chips, and wear- and heat-resistant coatings — so you drill deeper and faster in Ti-6Al-4V and other implant and aerospace alloys without pecking the cycle to death. Built for medical, aerospace, and watchmaking parts in the micron range.

Through-tool
coolant delivered to the cutting edge
No pecking
deep micro-holes in a single pass
Ti · SST · CoCr
titanium, stainless & implant alloys
Micro ø
small-diameter precision holes
Mikron Tool CrazyDrill micro-drilling a titanium part with through-tool coolant Mikron Tool · Micro-drilling titanium
Worked example
Titanium bone screw · T10
23 sec
1
Drill + 120° chamfer — CrazyDrill Hexalobe ø1.9 mm
n = 5,000 rpm · f = 0.05 mm/rev
2
Mill the lobe — CrazyMill Hexalobe ø0.4 mm (4 flutes), 3.5×d
helical XYZ · n = 50,000 rpm · vf = 225 mm/min · ap = 0.25 mm
3
Deburr — CrazyDrill Hexalobe ø1.9 mm
n = 3,200 rpm · f = 0.02 mm/rev
CrazyMill Hexalobe · Micro endmill

The endmill that mills the lobes — down to ø0.2 mm

A special micro-grain carbide with high stiffness and edge-chipping resistance lets this cutter run high feeds and aggressive stepover while holding the tight hexalobular profile from the first screw to the last. Three flutes on the smallest sizes, four above — in short (3.5×d) and long (5×d) lengths, with dedicated geometries for titanium, stainless, and cobalt–chrome. Same chrome-free eXedur SNP coating as the drill.

ø0.2–1.0
mm cutter diameter, T4–T30
3 & 4 FL
flute counts by diameter
3.5×d / 5×d
short and long reach versions
0.8×d
max pitch on helical interpolation
Implant alloys we machine
Ti Gr.5 ELI (Ti-6Al-4V) Ti-6Al-7Nb 316LM Stainless 316L Stainless CoCr (CrCoMo28) CoCr20W15Ni ISO 5832 implant alloys ASTM F1537 / F136
TORX® socket cycle time — titanium, CrazyMill Hexalobe 3.5×d*
T6
27s
T8
24s
T10
22s
T15
22s
T20
21s
T25
20s
Machining bone screws or implants? Let's cut your cycle time.
Send the screw print and the material — titanium, stainless, or cobalt–chrome. We'll spec the Hexalobe drill-and-mill pairing, the strategy, and the parameters, then prove the socket cycle time on your Swiss or mill-turn machine — under your disclosure terms.
Get support

Let's take work off your floor

Fighting stockouts, chasing cycle time, tired of a 1-800 catalog, or sizing up new machine capacity? Start a conversation with the independent team that handles all of it.

📞
978-356-2500
Mon–Fri, 7:30am–5pm ET
office@nsitools.com
📍
Ipswich, Massachusetts
Serving New England & the Northeast
🏭
Machines? Our sister company — lightsoutma.com
A real application engineer replies within one business day — or call 978·356·2500 now.