Precision Medical Mold Manufacturing

Where Microns Matter

SyBridge Technologies’ Saint Petersburg facility specializes in medical device manufacturing—an industry where tolerances are measured in ten-thousandths of an inch and surface finish quality directly impacts patient safety. The facility handles the complete mold production cycle, from soft turning and milling through heat treatment, hard milling, EDM, and final assembly.

“A lot of our parts are round,” David Bridges explains, describing the workflow that moves components through the shop. “A lot of times the part may start off turned out soft in the lathe department. Then it might go to milling or some other department before it goes to heat treatment.”

The precision demands are extraordinary. David points to a core component featuring radiuses of just ten-thousandths of an inch: “There’s a tremendous amount of shut-offs on this part, so it has to be made extremely accurately.”

Reaching the Unreachable

When conventional machining approaches fall short, SyBridge turns to Mastercam’s 5-axis capabilities. David demonstrates a part machined on their 5-axis Mikron, where Mastercam achieved seamless surface blending between a top diameter and tapered bottom section.

“Because of that tiny radius—probably less than a half millimeter—you’ve got to be in five-axis because you can’t get down there,” David explains. “So you are in simultaneous five.”

The Convert to 5-Axis feature proves particularly valuable, allowing programmers to start with familiar 3D toolpaths and then transform them for multi-axis execution. “You surface finish contour, and then convert it to five-axis,” David says. “Because these radiuses are very small, it’s really the only way we can get down there—wider than if we were to burn it.”

The Electrode Challenge

While SyBridge hard mills everything possible, some geometries—particularly square internal corners—require EDM. This means producing electrodes of extraordinary precision.

“These particular electrodes are about 25-thousandths diameter at the tip,” David notes, gesturing to a row of Mastercam-machined electrodes. “And we make some of them that go down to eight to ten-thousandths diameter at the tip. You just have to approach it in a certain way.” 

These electrodes, machined in 3 or 4 axes on their Roku mill, then drive the sinker EDM operations that complete the most intricate mold features. 

Confidence Before Cutting

With parts this precise and tools this delicate, mistakes are costly. SyBridge relies heavily on Mastercam’s machine simulation to verify programs before they reach the shop floor.

This upfront verification directly supports productivity. “Our goal is to keep the spindles running here in the shop,” David emphasizes. “The more upfront engineering we can do, the better for our productivity.”

From Programming to Production

By catching issues in the office rather than at the machine, SyBridge shortens development cycles and maximizes the value of their equipment. The multi-axis link feature ensures safe motion between toolpaths, particularly critical when working with the challenging length-to-diameter ratios common in medical mold components.

The result is a facility capable of producing medical-grade molds that others simply cannot match—where Mastercam transforms the seemingly impossible into everyday production.

About SyBridge Technologies

SyBridge Technologies is a nationwide mold and die manufacturer with facilities across the United States. The St. Petersburg, Florida location specializes in medical device molds and consumer products, featuring comprehensive capabilities including soft and hard turning, 3- and 5-axis milling, electrode manufacturing, and wire and sinker EDM. The facility includes on-site mold assembly and testing presses, enabling complete mold production and validation under one roof.

Quick Facts

• Product Used: Mastercam Mill, Mastercam Multiaxis, Mastercam Lathe, Dynamic Motion, Mastercam CONNECT Maintenance and Support Package
• Industry: Medical Device Mold Manufacturing
• Location: St. Petersburg, Florida
• Equipment: 3-Axis Mills, 5-Axis Mikron, CNC Lathes, Roku Mill, Wire EDM, Sinker EDM