Medical Implants & Instruments

Fusion has the unique ability to machine parts without oils, emulsions or synthetics. The Pure-Cut™ produces a dry, clean part while lowering operation costs, increasing productivity and improving operator environment.

Example: Titanium Medical Implant

Fusion Product:

Pure-Cut™

 Before Fusion:

15-minute cut-time with water-based coolant.

 After Fusion:

10.5-minute cut-time with supercritical carbon dioxide dry-cutting process. The Pure-Cut™ also improved tool life by 20%, reduced downstream cleaning operations, and eliminated the cutting fluid waste stream.

Results:

Reduced manufacturing costs by over 25%.

How We Improved this Process:

Dry-cutting with supercritical carbon dioxide has the lubricity of a semisynthetic cutting fluid. The combination of cooling and lubrication provided by Fusion’s Pure-Cut™ permitted faster feed rates while maintaining or improving tool life. Parts were machined dry and clean.

Aerospace, Defense & Power Generation

Increased productivity with Titanium, Inconel and other heat recalcitrant materials.

Example: A-286 AEROSPACE DRILLING

Fusion Product:

Pure-Cut™

 Before Fusion:

7-second cut-time and 50-cycle tool life with water based coolant.

 After Fusion:

1.5-second cut-time and 100-cycle tool life with supercritical carbon dioxide dry-cutting process.

Results:

4x productivity improvement, 2x tool life improvement, significantly reduced piece-cost and opened a new market.

How We Improved this Process:

Fusion helped develop a through-tool cutting process with 0.080mm-0.100mm diameter coolant holes. Pure-Cut’s™ unique solution mobility provided highly effective heat management where water-based cutting fluids could not. Supercritical carbon dioxide was able to penetrate, cool and lubricate the critical heat zones at the tool tip.

Automotive & Heavy Equipment

Increased productivity with carbon steel, aluminum, CGI and other common auto materials.

Example: 8620 AUTOMOTIVE MILLING

Fusion Product:

Pure-Cut+™

 Before Fusion:

600 parts per tool with dry-cutting process.

 After Fusion:

1200+ parts per tool with supercritical carbon dioxide and enhanced lubrication.

Results:

2x tool life improvement, saving the end-user over $1 million annually in carbide alone.

How We Improved this Process:

Lubrication was delivered more efficiently with supercritical carbon dioxide and significantly lowered cutting forces while reducing heat. Pure-Cut+™ with enhanced lubrication has MQL-level lubricity with near cryogenic cooling capabilities. Tool life gains were achieved while maintaining a near-dry cutting process.