FlexiFinish: Automated finishing for complex metal implants

What happens when finishing complex medical implants becomes too demanding to do manually, but precision and safety cannot be compromised?

At CROOM Medical, a manufacturer of high-precision orthopaedic implants in Ireland, post-processing has always been a critical but challenging step. Metal 3D-printed implants feature intricate geometries, delicate surfaces and tight tolerances. Removing supports, polishing and preparing them for final use is time-consuming, physically demanding and requires highly skilled operators.

But what if robotics could handle the most demanding finishing steps — while still allowing operators to collaborate safely and stay in control?

From challenge to solution

As part of the COGNIMAN project, a team of partners – IRT, Aldakin and NORCE – developed FlexiFinish, a robotic finishing demonstrator designed to automate post-processing of complex additively manufactured metal parts.

At its core, FlexiFinish combines sensors, planning algorithms and digital data integration to create a flexible system that adapts to each implant geometry. Its mission is clear: reduce operator workload, improve consistency and enable safe human-robot collaboration in finishing operations.

How Flexifinish works

• Geomertry-aware processing: The system uses CAD/CAM and Digital Twin data to understand each part and plan the optimal finishing strategy.
• Adaptive robotic finishing: Robots perform support removal, polishing and surface finishing while adjusting to variations in geometry and process conditions.
• Safe human-robot collaboration: Operators and robots share the workspace safely, allowing humans to supervise, guide and intervene when needed.

The result is a production environment where precision, efficiency and worker wellbeing reinforce each other.

The benefits at a glance

• Faster turnaround: Automation reduces post-processing time and increases throughput.
• Consistent quality: Controlled robotic finishing improves surface quality and repeatability.
• Improved ergonomics: Operators are relieved from physically demanding and repetitive tasks.
• Flexible automation: The system adapts to different implant geometries without complex reprogramming.
• Collaborative workflows: Humans and robots work together safely and efficiently.

A step toward smarter implant manufacturing

FlexiFinish is more than an automation tool. It represents a shift toward intelligent, collaborative finishing in advanced manufacturing. By combining robotics with digital data and adaptive control, it enables manufacturers to automate complex processes without sacrificing flexibility or safety.

Developed with real industrial needs in mind, this demonstrator shows how collaborative innovation projects like COGNIMAN can deliver practical solutions with impact across the medical manufacturing sector.