Machining titanium? Cast? forge?

[tri again]

I need to find a way to make a fairly complicated small thing out of titanium.

Let's just call it a medical device, implantable, with the bio-compatability of titanium.
or more accurately, least chance of rejection.

Maybe some lost wax method they use for intricate gold castings for rings and pendants and things we should ALL know about.
?
and then 'plate'? it with titanium?
"They' keep saying titanium but maybe smething else would work. idk yet.
Bone needs to want to grow to it.
New project so almost at a loss for where to even look.

I figure someone on here knows more than the rocket scientists.
I've heard it's brittle, difficult to machine and not conducive to casting or forging.

Thanks

[Chazz of Blades]

I take it that this medical 'device' would go into a hip?

Hmmm, there's a reason why titanium was an extremely hard thing to get started in production, and was valued more than gold for many years.

I think the saying is: "I could make an aluminum forge in my garage, I could make a titanium forge in my warehouse".

[tri again]

I take it that this medical 'device' would go into a hip?

Hmmm, there's a reason why titanium was an extremely hard thing to get started in production, and was valued more than gold for many years.

I think the saying is: "I could make an aluminum forge in my garage, I could make a titanium forge in my warehouse".

well?
Machining wise, it's about as complicated as
duplicating a tooth, roots and all, is what they're telling me.

They don't really want to tell me too much about it since there are millions ($) at stake.

I've just gotten the task of researching how to do it without knowing anything about it?
if THAT makes any sense.
ps
did you find a 200 br tank yet?
I'm not sure how to tell what my extra one fits.
I know I have an extra 200 es tank, but nothing to check it on.
I guess if it does NOT fit anything else, that would be it
but there's gotta be a better way.
I just ran a plastic mower tank on mine till I sold them and THEN got a new tank.

[Grindin' Gearz]

As a machinist by trade for the past decade, (half of which was spent making bio-medical implants, mostly spinal) I can tell ya machining titanium isn't that much more difficult than, say tool steel, solid carbide tooling and a petroleum based coolant is a must. The toughest part is polishing out your tooling marks, (the neat spirals mills and lathes leave behind) It's been my experience that failure to do so will lead to rejection and abnormal cartilage or bone growth, depending where the component is being implanted. Make sure your polishing is in steps, starting rough and finishing as smooth as possible. ALWAYS use a new wheel if your going to use Scotch Brite or similar product (polishing any other type of metal on that wheel will lead to impregnation which will lead to complications) And titanium being a "memory" metal, make sure to keep a cup of cool clean water around to avoid heating up your finished product too much. I know it may sound like a pain, but with practice and a degree of patience, I find titanium kinda nice to work with, as far as obtaining your material, I would ask around trusted suppliers, Yarde Metals, Thyssen Krup (not sure if I spelled that right) Anywho, hope this helps a bit, if you have any questions, feel free to shoot me a message, Id be glad to share whatever knowledge I may have, good luck!

[300rman]

I dont think plating Ti to another metal would be very effective for this. If the plating somehow got chipped, it could lead to other problems.

If this will be a one-off item, a machine shop is the way to go. If it is something that many will be needed, talking to a few manufacturing companies would be the way to go.

You'd need dies machined to be able to cast or forge the Ti part, and a plant that does casting/forging.

Machining a small, intricate 3D part is a royal pain, and polishing the final part will be even tougher. Im thinking a casting/forging will be your only options here.

Too bad Rapid Prototype machines cant make trailprotrailprotrailprotrailpro with metal, then you'd have this project in the bag, piece of cake.

[tri again]

Thanks everyone.
I am now thinking of powdered? is 'sintered' a word?
Like frangible cast/stamped bullets made of compressed metal powder.
We just don't want these new implants to come apart.
Compressive strength is more important than torsion for what it's worth.

I think I saw some discover channel episode where they were making funny parts out of
stamped (compressed) metal powder, for lack of a better description.

As far as finish, the bone compatible metal finished almost look bead blasted. so they seem rough.
Metallic crystalline rough? or blasted so they almost look porous?

This topic is new to me.
All I know is what I've described. They say pretend you need to make pieces as complicated as teeth,
including the roots.

The recalls from hip replacements came from 'one more' machining process and they forgot to
clean off the machine coolant, if you can believe that.

They usually temper or heat treat after all the work and that's what was
essentially sterilizing and cleaning off the oils and lube.
Incredible what a simple mistake can cause.

I also have NO problem sharing the wealth if this project comes to be.

[300rman]

compressed metal powder seems similar to forging. You would still need dies made.

[WilliamJ]

Sintering is indeed a word. Powdered metal (or other material) fused into the shape of a mould at high temperature but below melting temperature. Atomic diffusion occurs - no doubt there is a critical temperature range and possibly pressure at which this takes place.

I read that it allows fine control over the purity of the finished product. One relevant example (to trikes) is piston rings - but I doubt they are medical quality rings.

Titanium seems to be the material of choice for most orthopaedic bone repair work. My daughter has some installed. And look up selective laser sintering - clever stuff.
Bill

(Apologies for UK spelling)