3DSURF - AI-Driven Surface Treatment Optimization for Medical Device Manufacturing
PREMET KFT. is a Hungarian manufacturer of customized medical devices specializing in the production of titanium, aluminum, and veterinary implants using advanced 3D printing technologies. The company manages the entire manufacturing process in-house, from design and additive manufacturing to heat treatment and surface finishing processes, including sandblasting, etching, anodizing, polishing, and electropolishing.
As part of the 3DSURF experiment within AIRISE, PREMET KFT. sought to improve the predictability and sustainability of its implant surface treatment operations. By implementing an AI-powered optimization tool, the company aimed to reduce chemical consumption, improve process control, and support more consistent production outcomes while maintaining the high-quality standards required in the medical device industry.
Sustainable Medical Device Manufacturing
AI-driven Surface Treatment Optimization
PREMET KFT. surface treatment operations, particularly the chemical etching of customized implants, presented significant process control challenges. Unlike standardized products, each implant differs in size, geometry, and surface area, making it difficult to accurately predict acid consumption and monitor the condition of the etching solution over time.
The company sought a more predictable and data-driven approach to managing the etching process. Its objective was to reduce chemical usage while maintaining product quality, process repeatability, and regulatory compliance.
A further challenge was the collection of reliable process data. Measuring hydrofluoric acid concentration during etching is technically complex, requiring indirect measurement approaches and carefully designed validation procedures. In addition, the complex geometries of many implants made surface quality measurements difficult to perform consistently.
Within the AIRISE 3DSURF experiment, an AI-based decision support system was developed to assist operators in managing the implant etching process.
The solution uses simple process inputs to recommend the minimum amount of acid required for each operation while also predicting the resulting acid concentration after treatment. The AI model was trained using process data collected during extensive validation testing and was designed to support operators by complementing their existing expertise with quantitative recommendations.
The AI optimization tool, developed by Tecnalia, transformed complex process relationships into a user-friendly interface that could be easily integrated into daily operations. Throughout the project, AIRISE provided technical mentoring, project support, and documentation guidance, helping PREMET KFT. align the solution with both operational requirements and emerging AI regulatory considerations.
Regular collaboration between the project partners ensured that technical challenges were addressed efficiently and that the solution remained focused on practical industrial application.
- Reduced Chemical Consumption:
- Validation testing demonstrated that the AI system could significantly improve process predictability.
- The solution enabled an average reduction of approximately 33% in acid consumption during the etching process.
- Lower chemical usage contributes directly to reduced operational costs and improved environmental performance.
- Improved Process Predictability:
- The AI tool was able to estimate acid concentration within approximately 10% of measured values during validation tests.
- Operators gained access to a reliable decision-support tool that enhances process consistency and repeatability.
- The solution supports more informed decision-making during surface treatment operations.
- Enhanced Product Quality and Traceability:
- Data-driven process validation improves confidence in the quality and consistency of implant surface treatments.
- Customers, particularly in the medical sector, benefit from increased transparency and documented process control throughout manufacturing.
- The project strengthened PREMET KFT. reputation as an innovative manufacturer adopting advanced digital technologies.
Following the successful completion of the 3DSURF experiment, PREMET KFT. plans to further develop and integrate the AI optimization tool into its daily production operations.
Future activities include expanding the solution across all online surface treatment processes and exploring additional applications of AI within other manufacturing and finishing operations. The company also sees potential opportunities to offer advanced surface treatment services to other medical device manufacturers.
The project confirmed that AI can be effectively integrated into highly specialized medical manufacturing environments and will remain an important part of PREMET KFT. long-term innovation strategy. By combining advanced manufacturing technologies with AI-driven decision support, the company aims to further improve sustainability, process reliability, and operational efficiency while strengthening its position within the international medical device sector.