September 2010 - Level 3 Inspection

Archive for September, 2010

Orthopedic Implants

Orthopedic Implants
Orthopedic implant devices are some of the most challenging parts to inspect using traditional methods; until now. Level 3 Inspection can use White Light Scanning (WLS) with computer-aided-inspection (CAI) to compare the orthopedic components to the CAD model, other components and/or the product die. This technology gives our customers a new and profound insight into the size shape and geometric conformance of their products that they have never had before. By inspecting the entire surface of these components Level 3 can help their customers significantly reduce errors, control quality and dimensional consistency.
Level 3 Inspection’s SmartCompare and SmartFAI process gives their customers the ability to identify problems with a particular area of the part and focus efforts to improve problem areas without spending time and resources on areas that are known to be conforming. This is especially helpful when dealing with critical medical components, such as implants and broaches or rasps. The ability to quickly compare the product to the nominal CAD model as well as the ability to compare the products from multiple lots gives Level 3 Inspection’s customers an advantage in regard to quality control and time to market.
The Level 3 approach replaces traditional plate inspection or a CMM system with WLS, which can capture and calculate precise 3D, coordinates for millions of points in minutes.
CMM captures only a few points in the time that WLS can capture hundreds of thousands, so Level 3 is able to do a more thorough inspection. The results are much more visual and therefore much more easily understood and interpreted.
Inspecting medical implant devices with complex free form geometry poses some unique challenges, such as analyzing the complex surface areas of a newly manufactured part compared to the CAD model. This is difficult using a CMM system, which depends on the operator to accurately capture the points that will show whether or not the part is conforming within the allowable tolerance. Often, there is not enough point data to make an accurate comparison.
The new capabilities provided by computer-aided inspection have not come a moment too soon for the competitive biomedical implant device market. Increasingly, companies are facing the demand for more quality inspection results in less time, with the ability to visualize the results.
Level 3 Inspection’s customers are moving quickly to statistically based inspections in which the qualification is based not on a single piece, but on a sampling of parts, new part inspection would take much longer to complete without the ability to automate portions of the process.
Traditionally, studies based on a sampling of parts are done using CMM to generate metrics on dimensions for each part. This is a time-consuming process, since each part must be measured individually. Data is then typically transferred to an analytic program, evaluated, then published.
Level 3 is replacing the CMM-based process with automated trend analysis. Once a part is scanned and a report is saved, Level 3 can automatically generate portions of the capability studies defined by their customer or OEM specifications. Batch processing enables Level 3 to collect data and generate reports on a large number of parts. Statistical analysis tools allow Level 3 to compare parts for pre-defined factors such as repeatability, changes over time, and variations from part to part.
Speed is the key. Speed of inspection is always Level 3 Inspection’s main challenge. Everyone wants the results yesterday and our process is helping us deliver more complete results much quicker.
Contact us today to start getting superior inspection results in shorter time with easier understanding leading to higher confidence

WLS & CAI Applications In Orthopaedic Industry

Applications of White Light Scanning (WLS) & Computer Aided Inspection (CAI)
Ideas from Orthopaedic Industry Client Meetings, Projects & Discussions
Level 3 Inspection has pioneered the use of WLS and CAI technologies, combined with our component design and fabrication process expertise to deliver very advanced dimensional inspection capabilities. We are grateful for the variety of project opportunities we’ve received, and welcome any projects and all challenges to serve you.
Whenever we meet with clients we receive very enthusiastic suggestions about how our technologies and services can be used to solve problems. Several application ideas have been raised, and completed with rave reviews.
Biomedical and Orthopedic Parts we’ve successfully inspected:
  • Hip Stems
  • Hip Broaches
  • Acetabular Shells
  • Humeral Bearing Head – Shoulder
  • Complex Custom Screws
  • Foam Block Machine Tests
  • Knee/Femur Parts
  • Elbow Joints
  • Spinal Implants
  • Polymeric/Nylon Inserts
  • Wax Patterns
  • SLA Patterns
  • Cranial Drills
  • Tooth Implants (ceramic)
  • Device Components (bushings, extensions)
WLS & CAI Applications & Opportunities (examples not limitations)
  • Broach wear trending to show the rate of wear over usage life (& beyond)
  • CAD Model Creation – broach machining model, legacy parts, competitors parts, etc.
  • CNC Machine Program validation, new parts & legacy parts, with & without CAD models
  • FAI of Custom Implants & Joints
  • FAI of New Production runs, other parts of interest
  • Head Fragment Reconstruction
  • Investment Casting process inspection from tooling through FAI to Production Sampling
  • Instrument Services where some of vendors are delivering you less than perfect tools
  • Locking Feature Inspection
  • Parts & Tools that return from the field & need to be geometrically analyzed
  • Parts with Plasma-Deposition PA&HA coating – thickness measurement to show uniformity & deviation in the coating layer(s), surface finish calculation
  • Potted Hip Stems Alignment & Depth measurement
  • Production Tooling – direct wax die inspection for new acceptance or rework validation before you spend the time & investment to make castings
  • Statistical Process Control – Identifying the appropriate inspection schedule & sampling rate
  • Vendor comparison & Supply Chain Quality Problem Resolution
  • Absolutely anything where comprehensive & ultra-accurate surface digitization is important.
Level 3 Inspection offers technical services for proving out the application of these technologies and supporting developing an investment justification with actual results and financial benefit. Once the technical tools have been shown to have a business benefit, a WLS/CAI system can be specified, developed, proposed and implemented for your own use. We are structured to represent/resell, integrate, develop processes and file management solutions, train and support all of these technologies. We believe our 9+ years of parallel experience and expertise with these tools will serve you well. And we think the best way to get these applications proved out is to use our services to show the practicality they hold. Thanks in advance. We look forward to working with you.

Press Release – L3I Receives Prestigious Governor’s Award

Level 3 Inspection Receives Prestigious Governor’s Business Diversification Award
Program honors outstanding business contributions to Florida’s economy
STUART, FL(September 1, 2010) – Level 3 Inspection LLC is one of just 18 Florida companies to receive the Governor’s 2010 Business Diversification Awards for exceptional contributions toward statewide economic diversification. The award recognizes successful job creation and distinctive community involvement and investment efforts, many of which fall into industries Florida targets for economic diversification and high wage job growth. L3I was one of just three companies to win the Governor’s Entrepreneurship Award for Floridastart-up companies less than five years old, that have set a standard for entrepreneurship and creativity.
“We are very appreciative of this state-wide recognition for our rapidly growing business, and this will support our further expansion to better meet our client’s needs. We’re also quite pleased with the top-caliber of professional talent we’ve been able to attract here and the supportive business environment we’ve come to enjoy in Martin County.” said Bill Greene, CEO . “This is a great base of operations for our national and global high-precision dimensional inspection services and advanced computer automated inspection systems business.”
“This business award is a testament to a strong base of innovation and entrepreneurship that thrives in Martin County.” remarked Ron Bunch, executive director of the Business Development Board of Martin County (BDBMC), who expressed his support to the Governor. “We are extremely proud of Level 3 Inspection for their outstanding impact on the economy of Martin County and their dedication to innovation and expansion. We wish them much continued success.”
The awards will be presented September 22 in Tallahasseeduring Florida Governor Charlie Crist’s annual Industry Appreciation Week. The BDBMC will host a luncheon on September 24 to recognize the many contributions of local companies in targeted sectors.
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Level 3 Inspection, LLC (Entrepreneurship Award) – Martin Countywelcomed Level 3 Inspection to the county this year, when the company announced plans to hire up to 33 new employees and invest nearly $1M in its new location at Sawgrass Business Center. Level 3 Inspection is the world’s most proficient user of the 21st century measurement and inspection technologies of 3D White Light Scanning (WLS) and Computer Aided Inspection (CAI). The company pioneered much of the development of these tools, for world-class OEM and supply chain clientele. Level 3 Inspection boasts multiple patent applications already in process.
The Business Development Board of Martin County (BDBMC) is the county’s official economic development organization, and Enterprise Florida, Inc. partner. More information about the organization can be found by visiting
Enterprise Florida, Inc. is a partnership between Florida‘s business and government leaders and is the principal economic development organization for the state of Florida. Headquartered in Orlando, EnterpriseFlorida’s mission is to diversify Florida’s economy and create better-paying jobs for its citizens by supporting, attracting and helping to create businesses in innovative, high-growth industries. In pursuit of its mission, Enterprise Florida works closely with a statewide network of economic development partners.