In medical device manufacturing, precision, repeatability, and throughput are everything, especially when producing patient-specific implants. Acme Manufacturing’s (IMTS booth #237030) field-proven robotic, finishing, and polishing (RFP) series system transforms how custom knee implants are completed, combining advanced scanning, adaptive path generation, real-time compensation, and multi-step abrasive polishing to create smoother, longer-lasting components. By intelligently responding to each part's unique geometry, the system dramatically improves process efficiency and product quality, with measurable benefits for manufacturers and patients alike.From aerospace to orthopedics, Acme Manufacturing has spent more than a century engineering solutions for the most demanding material removal challenges. Now, the fourth-generation, family-owned company is transforming medical device manufacturing with its RFP Series Knee Implant Polishing System, which was recently deployed at Hammill Medical in Ohio. Dual-Robot Efficiency Powers Higher ThroughoutThe RFP System is engineered for efficiency. By utilizing dual invert-mounted robots, the system achieves a 100% increase in production output compared to conventional robot configurations, all while minimizing floor space. John McGrane, Acme’s Director of Marketing Communications, describes this new robotic system as “a culmination of what we’ve learned over building hundreds of systems, bringing in new technology and incorporating everything that was on the wish list for some earlier systems designed for medical device finishing.”Each implant undergoes a four-step abrasive belt finishing sequence, guided by light, responsive, and programmable compliance pressure for precise results every time. “We design and build all of our abrasive heads,” McGrane says. “That goes back to the Acme’s legacy equipment before robots were commercialized. We’re solving the dirty, dull, and dangerous, but robots are doing the work, not people.”These advancements come at a time when knee replacements and robotic-assisted surgeries are surging. A 2020 study reported a 210% increase in primary knee replacements compared to a decade prior, and the American Joint Replacement Registry recorded a 24.4% increase in cumulative procedural volume compared to the previous year. Robotic-assisted knee replacement surgeries account for approximately 13% of total knee arthroplasties today, and their adoption is projected to increase to 50% or more by 2030. Meanwhile, the orthopedic robotics market is forecast to exceed $1.09 billion by 2030. This highlights why precision manufacturing technologies like Acme’s RFP system are poised to shape the future of medical device production.Adaptive Auto-Path Generation for Custom PartsWhat sets this system apart is Acme’s auto-path generation technology. Each knee implant is scanned, and the robot generates a custom polishing path based on its unique geometry. This ensures consistent surface quality, improved implant geometry, and reduced rework – factors in medical device manufacturing where tolerances are tight and patient outcomes are at stake.“It’s not technically AI-based,” McGrane notes, “This programming method is adaptive in the sense that each part is scanned and Acme’s software is telling the robot what material needs to be removed based on a golden part model.” This adaptive approach allows the system to function intelligently, making real-time decisions that optimize precision and efficiency. The result: a predictable, repeatable process that lowers unit costs, extends abrasive media life by up to six times, and significantly increases production rates.Measurable Outcomes for Shops and PatientsFor Hammill Medical, the RFP system streamlines production, reduces operator fatigue, and frees skilled workers for higher-value tasks. These benefits ultimately translate into smoother, longer-lasting implants that can improve patient mobility and quality of life. “We’ve deployed more than 250 systems in the medical space,” McGrane tells us. “The Hammill installation combines lessons from hundreds of projects into one highly optimized solution.”The RFP Series also integrates components from multiple IMTS exhibitors, including FANUC Corporation’s (IMTS booth #338900) robotics, ATI Industrial Automation’s (IMTS booth #236144) tool changers, and workholding from SCHUNK, Inc. (IMTS booth #432010). This “ecosystem approach” allows Acme to combine best-in-class technologies into a single, turnkey solution. Acme At IMTS 2026With over 115 years in material removal, Acme remains a fourth-generation, family-run company, and is one of the earliest members of AMT – The Association For Manufacturing Technology, the owner and producer of IMTS. Acme’s robotic finishing expertise spans orthopedics, aerospace, firearms, consumer goods, and many other industries, but the RFP Series system shows how cross-industry knowledge can create medical device finishing solutions that help both manufacturers and patients alike.See Acme tackle the latest material removal challenges and meet Acme’s experts at IMTS 2026, September 14–19, at McCormick Place in Chicago. Register now at IMTS.com/Register.
Acme’s RFP robotic system doubles knee implant output with precision finishing, adaptive polishing paths, and integrated “real-time” process compensation technologies.
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