The MoonBro manufacturing process involves the following stages:
Raw Material Selection: The process begins with the selection of raw materials, particularly stainless steel. Stainless steel is available in different grades, sourced both locally in Pakistan and imported from countries like Germany, France, and Japan.
Magnetic Stainless Steel Usage: Different grades of magnetic stainless steel are utilized for specific instrument types. For instance:
- AISI 410/410X is used for gripping instruments like Forceps, Tweezers, and retractors.
- AISI 420A is employed for cutting instruments such as Bone Rongeurs, Chisels, and Scissors.
- AISI 420B is utilized for high-grade cutting instruments like advanced scissors and Bone Rongeurs.
- AISI 440C is reserved for high-quality cutting instruments like cutlery and measuring tools.
Non-Magnetic Stainless Steel Usage: AISI 304, a non-magnetic stainless steel grade, is employed for making instruments like Cannula, Clamps, Holders, Spreaders, and Suction Tubes.
Forging Process: The next step involves the forging process, which can be accomplished by hand or hammer forging. Different forging techniques, including Hot, Warm, or Cold forging, are chosen based on the instrument’s requirements. Forging shapes the metal parts of instruments/devices.
Milling and Turning: Milling machines are used to remove excess material and create features such as serrations, ratchets, male and female box joints, and grooves.
Filing, Grinding & Setting: Grinding wheels and files are used to eliminate irregularities, achieving the final shape of instruments. The initial setting of instruments is done by hand using various gauges.
Heat Treatment: Heat treatment is crucial to enhance instrument performance and strength. Annealing softens the material, while hardening/tempering processes increase durability. Instruments are heat-treated to achieve specific Rockwell hardness values.
Chemical Treatment: Chemical treatment, including pickling and passivation, cleans the surface and increases rust resistance.
- Pickling uses dilute sulfuric or nitric acid after heat treatment.
- Passivation involves immersing instruments in a solution to remove iron particles and restore corrosion resistance. Electro polishing can achieve this as well.
Fixing and Fitting: Instruments are aligned, fixed, and fitted to ensure accurate function. Sharp edges and burrs are removed.
Polishing / Buffing: Various abrasives are employed to create a uniform surface finish. Electro polishing enhances corrosion resistance and removes foreign substances.
Final Inspection: Qualified technicians perform a final inspection to ensure instruments meet desired specifications.
Marking / Labeling / Packaging: Instruments are marked using laser marking, etching, or screen printing. Proper packaging is done according to specifications.
Overall, the MoonBro manufacturing process encompasses careful material selection, precise shaping, heat treatment, and quality assurance to produce high-quality medical instruments.