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Faster, More Precise Dental Prosthetics with Advanced Coating Technology

Faster, More Precise Dental Prosthetics with Advanced Coating Technology

Perfectly milling high-quality dental prosthetics made from cobalt-chrome requires extensive expertise, including during tool development. Precision tool manufacturer ibb Zerspanungstechnik has now combined everything needed for a reliable and fast production process into its new solid carbide high-speed milling cutter, nearly doubling the material removal rate for end users. At the heart of this enhanced performance is a newly adopted solution from Oerlikon Balzers: the high-performance coating BALIQ TISINOS PRO.

Producing dental prosthetics is a prime example of precision engineering. Some bridges or implants fit perfectly onto the tooth stump without any adhesive, solely due to their exact fit. This precise shaping is essential for comfort and functionality in the mouth, so dimensional accuracy is the top priority from the very beginning, which includes using ultra-small dental tools. ibb manufactures CAD/CAM micro tools with micron-level precision and tailors them precisely – from cutting edge geometry to coating – for specific machining operations and materials such as cobalt-chromium (CoCr), titanium, zirconia, and glass ceramics.
 

Founded in 1985, ibb has earned a strong reputation in the global supply market. Whether small or large dental labs, milling centers, or dentists – ibb’s machining experts understand their customers’ specific requirements and reflect them in their product development. In 2021, ibb established a dedicated R&D department with a growing fleet of machines.

During testing in the ibb lab, high-speed cutters coated with BALIQ TISINOS PRO were used to machine special test specimens in CoCr blanks to measure dimensional accuracy.

Fast and reliable production under delivery pressure

Discussing the successful high-speed cutter test with BALIQ TISINOS PRO (right to left): ibb Sales Manager Jonas Kleinau, ibb CEO Tobias Zikoll, and Klaus Springer, Sales Manager at Oerlikon Balzers.

Fast and reliable production under delivery pressure

One of the R&D department’s key projects was enhancing a dental milling cutter for accelerated roughing of CoCr. “Our customers are constantly under time and delivery pressure. We want to support them with tools that enable reliable, high-speed processes, including unattended overnight production,” explains Tobias Zikoll, CEO of ibb, who represents the second generation of the family to run the business.

He knows that dental prosthetics are often produced on machines with limited performance, which cannot fully execute CAM-programmed curve speeds due to the irregular freeform surfaces of the components. So his goal was to accelerate the process by increasing the cutting depth while maintaining tool service life.

The resulting high-speed cutter was systematically optimized for roughing, from geometry and the carbide substrate to edge preparation and coating. To protect the surface, ibb chose the AlTiSiN coating BALIQ TISINOS PRO from its long-standing partner Oerlikon Balzers. Based on advanced, proprietary S3p technology, the coating produces an exceptionally smooth, defect-free surface with no droplets. Its modified microstructure and highly uniform thickness distribution ensure extremely stable cutting edges which are consistently protected – a key advantage for precision and performance, especially in micro-machining.

The high-performance coating is extremely wear-resistant and designed for hard machining up to HRC 70. It also withstands the high temperatures generated when machining CoCr and prevents built-up edges, even with materials prone to adhesion. “The market has responded very positively to the coating since we introduced it, and the transition from the previous product is already complete,” reports Klaus Springer, Sales Manager at Oerlikon Balzers.

Reducing roughing time by half with BALIQ TISINOS PRO

In ibb’s R&D lab, a high-speed cutter (2 mm diameter, 0.3 mm corner radius) coated with BALIQ TISINOS PRO was tested on a dedicated machine for roughing CoCr blanks using special test specimens to measure dimensional accuracy. When the results were compared to previous test data, the outcome was clear: with the same milling strategy, tool service life nearly doubled – or alternatively, the cutting depth could be doubled with an almost unchanged tool service life, effectively halving the roughing time.

Since spring 2024, ibb has used the new coating along with Oerlikon Balzers’ edge rounding service. “So far, we’ve received only positive feedback,” says Jonas Kleinau, ibb’s Head of Sales. “It’s a clear sign that staying close to customers continues to pay off. For us, that means we could even produce a small batch of two tools over the weekend,” adds Zikoll. Even packaging is considered: ibb has invested in producing entirely cardboard-based packaging to support its goal of climate-neutral tooling.

The dental prosthetics market continues to evolve, with more powerful milling machines becoming more popular – and ibb is already developing tools for them. “We’re glad to have access to Oerlikon Balzers’ comprehensive coating portfolio, which allows us to select the perfect solution for each application,” says Zikoll.

Reducing roughing time by half with BALIQ TISINOS PRO

In lab tests for roughing dental prosthetics in CoCr blanks, the new high-speed cutter from ibb coated with BALIQ TISINOS PRO doubled the material removal rate.

About ibb Zerspanungstechnik GmbH

Founded in 1985 by Herbert Zikoll in Lohmar, Germany, as a trading company, ibb has since evolved into a precision manufacturer. Today, the company produces solid carbide milling cutters and drills ranging from 0.3 to 40 mm in diameter, along with custom tools for high-performance machining in the automotive, aerospace, mechanical engineering, tool, and mold-making industries. The company’s main growth segment is ultra-precise micro tools for dental and medical technology. Production runs from 2 to 2,000 pieces are manufactured with micrometer precision on state-of-the-art multi-axis grinding machines. ibb is committed to top-quality products and being close to its customers.

https://www.ibb-gmbh.de/

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Petra Ammann

Petra Ammann

Head of Product Marketing Communications
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