Manufacturing Process
At Sinus Instruments, we pride ourselves on a rigorous and quality-driven manufacturing process. Every step—from forging to final packaging—is meticulously executed to ensure our surgical, dental, beauty, orthopedic, gynecology, and veterinary instruments meet international standards.
Forging
Our instruments begin with drop forging hammers using high-quality D-2 steel dies. The forged blanks then undergo ring trimming and acid pickling for clean, defined shapes.
Annealing
Forgings are visually inspected for accuracy before being annealed in vacuum furnaces, softening the steel for precision machining while preventing corrosion.
Milling
Once annealed, components are milled using custom cutters to add functional features such as serrations, ratchets, box joints, and more—ensuring perfect alignment and design accuracy.
Grinding
We use high-speed grinding wheels and belts to remove excess material and bring instruments to precise dimensions, preparing them for hardening.
Heat Treatment
Instruments are heat-treated in advanced furnaces to achieve optimal hardness without brittleness, meeting strict mechanical performance requirements.
Hardness Testing
Each piece undergoes Rockwell hardness testing using diamond-tipped equipment to confirm proper hardening and strength consistency.
Filling & Assembly
Components like forceps and scissors are assembled, aligned, and adjusted for flawless functionality, ensuring proper fit and movement based on master samples.
Electro Polishing
Instruments are electro-polished to smooth surfaces, remove burrs, and achieve a clean, corrosion-resistant shine.
Polishing
Experienced technicians use various polishing tools to give instruments their final smooth finish, whether mirror, satin, or matte.
Sand Blasting
Joints, ratchets, and teeth are sand-blasted for a matte look and added rust resistance—removing any visible surface imperfections.
Sharp Edge Cleaning
Sharp or unsafe edges are carefully removed to ensure user safety and reduce the risk of instrument failure during use.
Technical Inspection
Each instrument is functionally tested and adjusted for precise movements, alignment, and performance. Any that fail are reprocessed accordingly.
Passivation
To restore the protective oxide layer, instruments are passivated to eliminate any iron particles or contaminants that may affect corrosion resistance.
Final Polishing / Buffing
Instruments receive a final polish or buff—mirror, satin, or sand—as specified by customer or market standards.
Ultrasonic Cleaning
Finished instruments are ultrasonically cleaned to remove oils, grease, and polishing residues, ensuring a sterile, contaminant-free product.
Final Inspection
Each instrument undergoes detailed hand inspection to verify serrations, jaws, teeth, and functionality—including cutting and gripping performance.
Labeling
Approved instruments are marked via laser or stencil engraving as per client branding or traceability requirements.
Packaging
Instruments are manually cleaned again and packed in a controlled environment using sanitized conditions and protective wear. Each item is sealed, labeled, and prepared for dispatch, fully aligned with client requirements.
HRC Testing – Ensuring Steel Hardness at Sinus Instruments
After completing the vacuum heat treatment process, Sinus Instruments conducts HRC (Hardness Rockwell C) testing to confirm that the required steel hardness has been achieved. Proper hardness is vital to instrument durability and performance, and it varies based on the steel grade and heat treatment parameters.
Only when the specified hardness is met, the production batch is approved, and the HRC value is recorded on the lot tracking card for quality traceability and future reference.
Digital Rockwell Hardness Tester
This automated device delivers precise HRC readings within seconds using diamond indentation and a digital display, ensuring quick and accurate results.
Manual Rockwell Hardness Tester
A dependable, industry-standard tool known for its reliability and coverage across various instrument types, used frequently for sample-based HRC testing.
All vacuum heat-treated instruments must undergo HRC testing before advancing to the next stage of production.
Advanced Welding Technologies at Sinus Instruments
Sinus Instruments employs multiple welding techniques, each selected based on material composition, component profile, and functional needs of the instrument. These technologies ensure strong joints, seamless finishes, and enhanced performance.
Spot Welding
This resistance-based welding technique joins overlapping metal components—commonly used at the tail ends of tweezers (tissue forceps) using brass electrodes to create clean, secure weld points.
Argon Welding
Applied in tungsten carbide (TC) instrument production, argon welding ensures a strong, clean bond between TC rods and stainless steel scissors, delivering long-lasting durability.
Laser Welding
A high-precision technique used for both instrument repair and component assembly, laser welding uses a focused laser beam to create fine, accurate welds with minimal heat distortion.
Induction Welding
A high-tech process utilizing electromagnetic induction, ideal for welding Tungsten Carbide inserts to stainless steel tools like needle holders and forceps. It’s both efficient and visually captivating in operation.
