Surface Finishing using Dry Electro-polishing Machines
Kemet now offer a non-abrasive, dry electro-polishing surface finishing system, capable of substantially reducing surface roughness whilst maintaining the geometry and tolerances of the components. Compared to the multiple steps often required with mechanical surface finishing, this new technology offers fully automated polishing to a mirror finish in one step, and is more effective than liquid electro-polishing which generally reduces surface roughness by only 50%.
Dry Electro-polishing in the Medical Sector
The Medical sector requires clinically proven processes and products which guarantee compliance with the most demanding health and safety regulations. Manufacturers must ensure that the devices meet all legislated requirements and in particular perform risk/benefit analysis to evaluate biocompatibility and toxicity of materials used.
Medical devices and components often require high quality surface finishing and a non-aggressive process is required to avoid damage. A dry electro-chemical process is perfect for such applications, offering more control than liquid electro-polishing and working efficiently at the micro and macroscopic level.
DLyte has proven the biocompatibility of the products processed with DLyte System. The study has been made according to the specifications of standard UNE-EN-ISO 10993-5:2009.
Comparison Surface Finishing Process for Machining Implants
Kemet also offer Vibratory Finishing Machines for pre-processing before the Dlyte stage
Finishing Solution for a wide range of materials
Dry Electro-polishing DLyte can achieve a high quality finishing for machined, sintered and casting parts, offering mirror finish results, the polishing action reaching every corner of the piece and processing inner cavities which cannot be accessed mechanically.
Preserving the geometry of the cast or machined component without rounding edges, Dry Electro-polishing can remove grinding patterns to deliver brilliant, mirror-like finishes with predictable costs. It offers the ability to process complex geometries without leaving micro-scratches on the surface, while maintaining component tolerances.
Solution for the most common metals and alloys in the industry, such as Cobalt Chrome, Stainless Steel, Carbon Steel, Nickel Alloys, Copper Alloys, Titanium and Nitinol
Electrolyte Media
The DLyte technology works with different electrolytes for each material and designed for different specifications.
| Electrolytes | Material |
|---|---|
| CoCr Group - CoCr01 | CoCr alloys |
| CoCr Group - CoCr02 (Only for mirror finishing and complex geometries) | CoCr alloys |
| SS Group - SS01 | Stainless Steel alloys |
| SS Group - SS02 (Only for mirror finishing and complex geometries) | Stainless Steel alloys |
| Ti Group - Ti01 | Nitinol and Titanium alloys |
Electro-polishing Machines
DLyte 1 - 100 Series
New patented machines for grinding and polishing Stainless Steel, Cobalt Chrome, Nitinol and Titanium.
| Code | DLyte1H/1l | DLyte10H/10l | DLyte1H+/100l |
|---|---|---|---|
| Capacity | 75Ø mmx50mm (maximum volume centered to the axis) | 120 Ø x 50 mm (maximum volume centered to the axis) | 180 Ø x 80 mm (maximum volume centered to the axis) |
| Machine dimensions (mm) | 510 x 1150 x 690 | 820 x 1280 x 680 | 950 x 1410 x 730 |
| Support dimensions (mm) | 510 x 690 x 680 | 820 x 680 x 680 | 950 x 700 x 740 |
| Machine weight | 96 kg | 173.5 kg (230 V) - 193 kg (110 V) | 217.5 kg (230 V) |
| Support weight | 47 kg | 87 kg | 100 kg |
| Power | 2 kW | 3 kW (single phase with industrial plug) | 5 kW (single phase with industrial plug) |
| Voltage | 220-240 V | 220-240 V | 220-240 V |
| Air pressure | - | 4-5 bar (air connector: 8mmØ or 1/4’ BSP’) | |
| Series Model | Materials | Frequency |
|---|---|---|
| DLyte1H, DLyte10H, DLyte100H | For Stainless Steel and Cobalt Chrome | LF |
| DLyte1HTi, DLyte10HTi, DLyte100HTi | For Nitinol and Titanium | HF |
| DLyte1H+Ti, DLyte10H+Ti, DLyte100H+Ti | For Stainless Steel, Cobalt Chrome, Nitinol and Titanium | LF and HF |
| DLyte1I, DLyte10I | For Steel, SS, CoCr, Nickel and Precious Metals | LF |
| DLyte1ITi, DLyte10ITi | For Titanium | HF |
| DLyte1I+Ti, DLyte10I+Ti | For Steel, SS, CoCr, Nickel, Titanium and Precious Metals | LF and HF |
| DLyte10ICs, DLyte100ICs | For Carbon Steel | LF |
| DLyte10I+Cs, DLyte100I+Cs | For Steel, SS, CoCr, Nickel, Precious Metals and Carbon Steel | LF |
| DLyte10I Ti+Cs, DLyte100I Ti+Cs | For Titanium and Carbon Steel | LF and HF |
| DLyte10I +Ti+Cs, DLyte100I +Ti+Cs | For Steel, SS, CoCr, Nickel, Titanium, Precious Metals and Carbon Steel | LF and HF |
PRO Series - DLyte PRO 500
A high capacity compact surface finishing machine, the DLyte PRO 500 polishes the most common industrial metals and alloys used in industry: Cobalt Chrome, Stainless Steel, Carbon Steel, Carbides, Nickel Alloys, Aluminium Alloys, Copper Alloys, Titanium, Nitinol.
- High performance - Three different configurations.
- High capacity - 750 Ø x 330 mm (Maximum working area).
- Advanced automation - IoT Software and quick fixing holders.
- Automatic extraction and cleaning system - While components are extracted, an air flow blade removes media stuck to the surface avoiding undesirable marking of the surface and allowing re-use of the media.
- Multiholder - One system, multiple applications.
- Planetary rotation - with variable and independent speed and motion sensors.
- Quick coupling - For easy plug and release of the holders.
- Easy media handling - Container with media can be loaded and unloaded with a pallet truck.
- Easy access - The design facilitates the access to the internal components for easy maintenance and operation.
Solution for Mass Production Electro-polishing - DLyte 10,000
The DLyte 10,000 modular machine can be fully integrated into your production line, offering high capacity and automation and continuity into existing mass production systems.
Electrolysis workstation
- Rotational Tank + Base
- Capacity of 1200L
- Diameter: 1330mm / Height: 850mm
- 6 r.p.m. clockwise & counterclockwise rotation
- Vibration system
Machinery guard system
- Safeguarding the work process
- Automatic machine stop in case of door opening
- 2006/42/CE Compliance
Robot for complex and large geometries
- 1 piece up to 750 x 500 x 500mm
- Maximum load: 100 Kg
Crane for mass production
- 200 pieces up to 50 x 50 x 50mm
- Maximum load: 1000 Kg
- 4, 6 and 8 holders configurations according to dimensional and capacity requirements
How Dry Electro-polishing Works?
Dry Electro-Polishing offers an improvement on traditional finishing systems, simplifying the polishing process of metal parts with a new patented technology, surface finishing metals by ion transportation. The components are held by positively charged clamps and immersed in constantly moving media particles in a negatively charged container. Containing an electrolyte liquid, these conductive, porous particles absorb the metal being electrically removed from the peaks of the components’ rough surface. As well as being a one stage process, Dry Electro-Polishing maintains component edge integrity and penetrates/polishes internal areas that cannot be accessed by traditional methods.
The system works efficiently at micro and macroscopic level
Before Dry Electro-polishing
After Dry Electro-polishing
Step 1
The parts are fixed on the holder
Step 2
The holder is introduced in the machine
Step 3
Select the program
Step 4
Average of 50-60 minutes time cycle
