Our process
Die forging of raw forged implant blanks
Die forging is a technique used to create a part by applying significant force to a metal bar, either cold or hot, in order to shape it into the desired form.
It does not allow for the same tolerance levels as machining, but the resulting parts are more resistant to mechanical stress because the deformation of the metal leads to work hardening, which in turn causes grain flow within the material.
Forging vs Casting
The main advantage of forging over casting lies in the shaping of the internal structure of the steel, resulting in superior mechanical properties.
Currently, it is the only technology capable of meeting the requirements of ISO 7206-4 and ISO 7206-6:2013 for fatigue testing of forged hip prostheses.
Components subjected to high stress, particularly fatigue stress, often need to be oversized when cast compared to when they are forged.
Forging vs Machining
Machining is performed on raw material stock. Upon delivery, this raw material is always fibred in the longitudinal direction, due to the production process of the bars.
When parts are machined from this raw stock, the grain flow is cut, which weakens their mechanical strength.
As a result, components subjected to high stress, particularly fatigue stress, often need to be oversized when machined compared to when they are forged.
The Specificity of FORGINAL Medical
Precision Forging
FORGINAL Medical uses Montbard board-drop hammers: 850 kg, 1000 kg, and 1250 kg.
Unlike screw or hydraulic presses, this type of equipment allows the production of anatomical prostheses with a thickness tolerance of ±0.1 mm, a precise and consistent surface finish—particularly for finned or toothed shoulder prostheses—and a significantly lower raw material usage compared to other forging technologies (approximately 1/5 less).
The rotary table furnaces are all computer-controlled, ensuring perfect uniformity in temperature preparation for each billet before forging. This is especially critical for titanium parts, where even a few degrees of variation can lead to major defects.
Small-Batch Forging
We also offer the unique capability of forging very small production runs starting from just 25 pieces.
Our decision not to automate certain workshops allows this flexibility. In fact, automated systems require setup times that are only justifiable for large-scale production.
FORGINAL Medical has therefore chosen manually operated precision drop hammers.
High-Tech Forging
FORGINAL Medical is a subcontracting industry. Its mission is to manufacture your components in strict compliance with your requirements and specifications.
Our expertise lies in supporting your projects and applying our knowledge of high-tech forging processes.
FORGINAL Medical does not offer its own range of implants on the market. Instead, we focus on bringing your projects to life and producing your custom prosthesis lines.
