Atlantis production tour in Waltham, MA (USA)


welcome to DENTSPLY Sirona implants my
name is chad Hebert I’m an Operations Manager here we’re in Waltham
Massachusetts just west of Boston and today you’re gonna get a special look
deep inside of our processes and meet some of the critical staff along the way
come on let’s go for a ride all right here we are in receiving and order
verification what happens here is it’s 20% of our cases that come in we receive
physically the other 80% of digital but we got to do a check to make sure that
the product is correct Jason tell me what goes on in this area so in this
area this is basically where the physical order will first come in the
case pans will come in we have a case pan person who opens up the boxes they
take that material out of that box put all that material for that customer in a
case pan and they pass it on to the receiver and the receiving personnel
will then go ahead and scan in what we call a ship ticket that ship ticket will
give it a unique number and that number will go off into the order verification
area with the product and our order verification technician is responsible
for basically checking that order verifying that everything that we
request has been done if it’s straight forward that case will then be sent off
into our scanning Department it will be scanned and that is how the actual model
becomes digitized that would line up the process for the other 80% that we do
exactly alright so now that we have everything digitized we’re gonna head on
over to do some digital manufacturing using our custom VAD software in the
design department hey Betina – Hey Chad, what’s up. So tell me about the
superstructure product that you’re working on right now so superstructures
are multiple implant-supported restorations for the full edentulous
or partially edentulous arches that we are fabricating in two ways additive
manufacturing and milling and we are offering several products from removable
to fixed, everything that is for the restorative need of the dentist so this is a
one-off this is a custom designed structure just for one patient and one
patient only – and we do these all day long digitally? all day long digitally Thanks for the information Bettina I’m gonna go check out abutment
design now see you later. Hey Victoria Hey Chad. Looks like you have some fancy software here on
the screen, what’s so special about it I do actually this is VAD our software
virtual abutment design and as you can see I’m designing two abutments here
and what’s so special about it is that if we violate a regulation meaning that
abutments cannot be milled, it gives us a warning and sometimes you
have to contact the customer to if the case for some reason has issues that we
cannot resolve on our own as a ADC’s we do need their that’s our main job is to
contact the customer and resolve issues now that we’ve seen how we do our
digital manufacturing we’re going to move into some physical manufacturing
we’re gonna visit titanium machining first come on let’s go hey Dave there’s a lot going on here, can you tell us a little bit about that sure, here in Waltham we produced the
Atlantis custom abutment for the entire North American market we also have a
facility in Sweden where we produced our product for the European market and a
facility in Tokyo where we support Japan that must take a lot of automation it
sure does we’ve developed automation for all of
our equipment to enable these machines to run 24/7 whether there’s somebody in
the building or not so how do we ensure their quality well we have a final
inspection procedure that we perform over in our metrology department can we
go check that out? sure let’s go all right in particular
this CMM machine is interesting, can you tell us about it
sure the CMM is a coordinate measuring machine what this does is this allows us
to fully inspect and measure all the critical dimensions of every abutment
interface and why is that so important? well for one thing it’s an FDA
requirement for us to maintain this quality data, but the other thing is
really, these things are going into a person’s mouth and this is intended to
be with them for the rest of their life that’s awesome Dave now we’re off to
Zirconia operations. Hey Peter, how are you doing today? Great Chad, and you? I’m Great. Tell me about this area what’s going on in here?
Oh we do a lot over here, we make zirconia abutments we also make zirconia crowns, a little bit of the Azento product? oh definitely, that’s a big product for us this year I hear some piloting and R&D is also in
this room? oh that’s that’s huge for us when we have a new product or a new idea, we work with them to develop the equipment, develop the process
industrialize the process to ship the customers. So very integrated with
development and also operations right in the middle. Thanks so much Peter. You’re welcome Chad. All right next stop we’re off to the advanced manufacturing center of
excellence, let’s go check it out alright here we are we’re at the new
advanced manufacturing center of excellence we’ve got a ton of new
manufacturing equipment here 3D metal printing, different types of resin
printing and we’ve got a whole bunch of new manufacturing processes that are
being introduced into this area. It’s gonna be a whole new magical place for
us to build product. Come on in. The really exciting thing we’re doing here
is we’re doing 3D metal printing so today we’re gonna talk to Brian Sullivan
one of our operations engineers to get into the details of it. additive
manufacturing is really you know an emerging and disruptive technology one
of the advantages of this process is that it isn’t constrained by some of the
design requirements of other manufacturing processes so that really
enables you to make the geometry that you can’t really make with other
processes the way the geometry is formed with this process is really kind of it’s
digitized so you’re breaking things down into slices and then you’re kind of
conforming the way it’s put together so that’s like automating the geometry
generation. what does it mean for the customer? really it enables you to get
you know cost efficient and timely production of patient specific
geometries. all right, so like I mentioned before we also have resin printing this
here is where we do our Simplant guides for our new Azento product and Brian’s going to tell us a little bit more about the difference between resin printing versus
metal printing. Sure, so basically they’re both laser based processes the
resin based printing is it’s a photopolymer so basically the UV laser
is polymerizing the resin into a solid where the metal can be thought of as
more of like a micro welding process so basically you have powdered metal and
the laser is actually melting all the particles together. Thanks Brian, all
right, so now that you see in the center of excellence we’re gonna see how all
the products come together and go into our quality control department out the
door to you so now we’re coming into our quality
control and shipping department this is where all of our products get married together
doing an inspection before we ship it out the door this place looks like it’s
pretty automated can you tell us a little bit about that Jason? Sure, so
yeah we do have a couple of integrated systems here you know and it’s very
self-explanatory and it just helps the operator you know in order to get the
job done without any problems or any errors
awesome that must totally help us out our FDA regulations that we have – oh
definitely I mean especially when you have a medical device that is going into
a patient’s mouth we have to make sure we have that clearance from digital manufacturing to physical
manufacturing you guys have seen it all so I just want to thank you for coming and
visiting Dentsply Sirona implants, and until next time, I got work to do.
see you later

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