How Flexxbotics is transforming orthopedic implants manufacturing

Flexxbotics, delivering digital solutions for robot-driven manufacturing at scale, today announced that Mach Medical, a medical device contract manufacturer transforming the orthopedic supply chain, has deployed Flexxbotics for advanced robotic machine tending with autonomous process control. Using Flexxbotics enables Mach Medical to further optimize the High Velocity Single-Piece Flow Manufacturing approach – delivering precision, speed, and compliance at scale.

By integrating Flexxbotics’ platform into the production process, Mach Medical has achieved a fully autonomous, multi-machine workcell capable of 24/7 lights-out operation. The cell includes 5-axis vertical milling operations, a Coordinate Measuring Machine (CMM) for in-line inspection, and a custom part wash/blow-off station – all orchestrated by a single robot using Flexxbotics technology.

The automation cell implementation has already resulted in a 61% increase in production capacity, a 44% boost in throughput, and a 20:1 machine-to-labor ratio – delivering high-quality joint replacement implants with precision and consistency.

“As we continue to scale out operations, robotic digitalization is a key pillar in our smart factory strategy,” says Stephen Rozow, general manager & co-founder of Mach Medical. “We view advanced robotic machine tending with Flexxbotics as a real enabler of our expansion and efficiency plans.”

Mach Medical was founded to change how orthopedic implants are manufactured and delivered. By providing implants with a 3-week lead time and flexible lot sizes as low as one unit, Mach Medical helps orthopedic OEMs reduce inventory by up to 83% – with inventories costing OEMs an amount equivalent to 8% of sales or more, the savings start rivaling the OEMs R&D budgets. Achieving this level of agility requires a manufacturing system that can dynamically manage multiple SKUs, integrate inspection and compliance in-line, and provide full traceability – all of which Flexxbotics enables.

The Flexxbotics solution gives the Mach Medical robots full command and control over the workcell, connecting directly with all equipment and systems. Closed-loop feedback from CMM inspection results is automatically routed to CNC machines in real-time, allowing continuous, autonomous operation with full FDA compliance, including Device History File (DHF) traceability for each implant.

“We are proud to partner with Mach Medical to help them enhance their High Velocity Manufacturing capabilities. We understand that next generation manufacturers in high-precision industries require multi-machine orchestration for multiple parts and operations,” says Tyler Bouchard, CEO & co-founder of Flexxbotics. “That’s why Flexxbotics enables advanced robotic machine tending to transform basic tending into robot-driven manufacturing at scale.”