Tight Tolerances Makes Drilling Safer

DrillStop is a patented dental instrument designed by Dr. Emil Verban used for dental implant procedures. The device provides a precise method of drilling for accurate implant placement avoiding drilling too deep. Marshall Manufacturing Co. produces the DrillStop for Dr. Verban.

As the popularity of dental implants has grown, unique instruments have been designed to make the procedure more precise, safer, and with higher patient satisfaction. One of these developments is the DrillStop, designed and marketed by Dr. Emil Verban and manufactured by Marshall Manufacturing Co.

A practicing dentist with an implant specialty, Dr. Verban recognized the need for a precise method of drilling for accurate implant placement while avoiding drilling too deep. Dr. Verban developed his concept in the early 2000’s using plastic tubing for his early prototypes. With the help of retired machinist Alan Shears, Dr. Verban refined a stainless steel DrillStop design using a unique collar that stops the drill at a preset location preventing it from drilling too deep. A tiny setscrew locks the stop to the drill bit. In use, the stop rotates with the drill bit while avoiding tissue damage as the drill penetrates the bone. The DrillStop, made from surgical stainless steel, are autoclavable and reusable, and are available in a kit with sizes for 8mm, 10mm, 11.5mm, and 13mm depth control.

When Dr. Emil Verban researched possible sources for machining his patented DrillStop, he chose Marshall Manufacturing because they were a registered medical device component manufacturer with complete Swiss machining capabilities. The part geometry of the DrillStop requires numerous turning and milling operations best suited to the newer multi-function Swiss machines with which Marshall Manufacturing is equipped. Their machines could perform all of the needed operations on one machine in a single setup. Plus, with Marshall Manufacturing’s medical device manufacturing expertise, they were able to suggest process changes that made the product easier to manufacture and improved the product performance.

In addition to milling, drilling, and turning, these multi-function machines can perform braoching, honing, knurling, burnishing, hobbing, thread whirling, and thread rolling.

“We chose Marshall Manufacturing because of their up-to-date capabilities and willingness to help us with our early prototypes,” states Dr. Verban. “These included the efficient planning of the machining for all 22 components in a DrillStop kit. Marshall’s manufacturing experience resulted in improvements to the component finishes and the addition of laser marking for permanent product identification. To sell the DrillStop successfully to dentists, the product required manufacturing to professional dentistry standards, demanding a high degree of part accuracy, done efficiently and cost effectively by an ISO 13485 registered source.”

Dr. Verban designed the DrillStop collars in a range of diameters and lengths to accommodate different implant requirements and to fit the range of drill bit sizes customarily used by dentists for these procedures. The collar diameters range from 6mm to 13mm and collar lengths from 10mm to 14mm. (DrillStop do not include drill bits which are purchased separately).

Marshall Manufacturing machines these collar components on their Citizen L20 Swiss machines equipped with CAV20-IS bar feeders. Designed for ultra-precision, high productivity work, these machines have a main spindle and secondary spindle that share machining operations. The main spindle offers maximum rotational speed of 10,000rpm while the secondary spindle offers 8,000rpm.

A Drillstops kit has collar diameters from 6mm to 13mm and lengths from 10mm to 14 mm. For highest quality and cost-effectiveness, this product is manufactured in Marshall Manufacturing’s ISO-registered facility using Citizen L20 Swiss machining centers.

Design of Citizen CNC Swiss machines are designed for small-diameter parts like the DrillStop collar. The guide bushing provides workpiece support at the point of the cut and minimizes workpiece deflection and vibration while holding very precise tolerances. In addition to milling, drilling and turning, these multi-function machines can perform broaching, honing, knurling, burnishing, hobbing, thread whirling and thread rolling; and in return often eliminate the need for secondary operations on another machine.

Machining of DrillStop components are from 303 stainless steel in 12ft bar stock lengths in 3/16" and ¼" diameters. Used in the manufacture of dental implants, 303 stainless steel is an FDA approved material.

Marshall’s single setup Swiss machining operation of the DrillStop include turning O.D. to size by the machines primary spindle, followed by facing, drilling, and boring to specified depth. A cross hole is drilled and tapped for the DrillStop setscrew. Milling of a flat occurs on the part with the machines end mill. The machines secondary spindle then collets onto the part at which point the part is cut from the bar stock. The secondary spindle then faces off the backside of the part, puts a radius on the parts outer diameter and the parts inner diameter through-hole.

Spindle speeds vary according to the operation and ramp up to the machine maximum where possible. The machining process takes less than two minutes per part. Accuracy on critical surfaces is 0.0005". Certain parts in the kit of DrillStop components are bead blasted to a matte finish to minimize glare when in use while others in the kit are laser marked for easy identification. As a final step, passivation of all collar components are done to remove impurities on the surfaces to avoid corrosion.

Dr. Emil Verban has practiced dentistry for 35 years and owns McLean County Dental and DrillStop, in Bloomington, IL. His specialized dental instrument designs make implant procedures easier and safer, and with more satisfied patient outcomes.

Currently, DrillStop sell through specialized dental supply companies including Blue Sky Bio and Osseous Technologies of America.

“DrillStop have been used successfully by dentists for more than three years,” reports Dr. Verban. “More than 200 dentists in the U.S. and Puerto Rico now use DrillStop. Were pleased with Marshall Manufacturing’s help in this success and are now working with them on another unique dental instrument we hope to announce soon.”

DrillStop
Bloomington, IL
drillstops.com
 

Marshall Manufacturing Co.
Minneapolis, MN
marshallmfg.com