Beagle Orthopaedic digitises cutting process

Beagle was established in 2008 with the primary aim of developing and producing braces for the NHS. Their commitment to providing the best orthopaedic products to patients with unparalleled support has been their philosophy for over 15 years. Over time, the company has expanded its range of products and customers, and today, it boasts a turnover of £6 million with a team of 75 employees. To sustain their growth and stay ahead of the competition, Beagle has embarked on a digital transformation programme aimed at increasing efficiency and optimising the production of their quality products. This initiative will continuously improve patient outcomes, whilst also advancing the company's sustainability goals. Their investment in innovation, research, and product development will enable Beagle to expand into new markets while maintaining their position as a leading manufacturer in the UK.

Beagle assessed their current processes and explored new manufacturing methods; they concluded that digital cutting is the best way forward for their business needs. Beagle's digital transformation journey reached a significant milestone with the installation of a Zünd G3 L-2500. This technology will enable Beagle to facilitate digital manufacturing and provide opportunities for the growth and development of its skilled workforce. The current skill sets will be upscaled, with new roles created in design and technology to keep Beagle at the forefront of innovation.

Beagle Orthopaedic has always invested in its growth to ensure they stay at the forefront of the orthopaedic industry in terms of innovation, research, and product development. Upon reviewing its production processes, Beagle recognised the potential benefits that a digital transformation program would offer, leading to a more effective and efficient manufacturing process.

Phil Smith, Production Lead at Beagle Orthopaedic said “This year, we decided to digitise our manufacturing process, to give us more flexibility and optimisation. We have used a clicker press for the past 15 years, however, tooling is expensive and has a long lead time, slowing down manufacturing production timings. We wanted a more all-consuming cutting solution which will provide an increase in productivity and less material waste.”

Phil also added “A more versatile cutting solution will improve planning and optimise material usage by using a digital toolset. Without the long lead times for tooling, we can produce and develop both stock and bespoke devices quicker and more efficiently”.
The next step for Beagle was to find a supplier and cutting device that met their requirements, including a strong support network of trained technicians in the UK.
Phil said “Digital cutting offered excellent accuracy and repeatability. This is a significant investment for us, so we did our due diligence and contacted nearly all manufacturers of digital cutters and we shortlisted three manufacturers including Zünd. What set Zünd apart was the full turnkey package and modularity in all areas, from additional tooling, software and training”.

The team at Zund UK, located in Letchworth, conducted cutting trials on a variety of materials such as elastics, foams, neoprene, and cotton. Their effective communication and positive results provided confidence to Beagle, making Zünd the preferred supplier. The Zünd G3 L-2500 offers a higher level of accuracy, cleaner and sharper lines and more design flexibility, allowing Beagle to design and shape their braces with ease.

Beagle Orthopaedic received their Zünd G3 L-2500 cutter in July 2023 and has already seen the benefits of using a digital toolset.
Phil said “Our production process has improved in terms of speed and quality of finish. With several hundred parts requiring conversion from knife templates to digital files, we expect the initial hard work to pay off very quickly in time and money. We are also now able to improve supply chains using UK-sourced raw materials, which will help us to reduce our carbon footprint”.

Beagle is also benefitting from the Zünd G3 L-2500's projection system, “Our Zünd cutter’s part differentiation function allow our operators to retrieve the parts in an organised and systematic structure allowing us to control the process for optimal results”.
Reflecting on the purchase, Phil said “We are very impressed with our digital cutting workflow and how it has enhanced our manufacturing process. The ability to nest several parts and being able to achieve the best yield will help us reduce our material wastage and achieve our net zero targets by 2050”.