Category Archive: Double-Disc Grinding

How Nifty Bar Elevates Medical Manufacturing

How Nifty Bar Elevates Medical Manufacturing

In the rapidly evolving field of medical manufacturing, precision and reliability are paramount. Nifty Bar offers a suite of specialized services that cater to the stringent demands of the medical industry. With expertise in Double-Disc grinding, Nifty Bar is an invaluable partner for manufacturers of medical, orthopedic, and dental parts, ensuring high-quality, consistent, and efficient production.

Orthopedic and Dental Plates: Precision Matters

Orthopedic and dental plates are critical components used in surgeries to repair and stabilize bones and teeth. These medical devices require exceptional precision and reliability to ensure patient safety and successful outcomes. Nifty Bar understands the high stakes involved and provides advanced manufacturing solutions to meet these needs.

Orthopedic Plates:

  • Accuracy and Consistency: Nifty Bar’s precision grinding ensures that orthopedic plates are manufactured to exact specifications, minimizing variability and enhancing the fit and performance of implants.
  • Material Integrity: Utilizing Double-Disc grinding, Nifty Bar maintains the structural integrity of high-strength materials, ensuring durability and longevity of the plates.
  • Surface Finish: A superior surface finish is crucial for orthopedic implants to reduce the risk of infection and promote better integration with the body. Nifty Bar’s techniques achieve a smooth, precise finish that meets medical standards.

Dental Plates:

  • Customization: Dental implants often require bespoke solutions tailored to individual patients. Nifty Bar’s precision capabilities allow for customized production runs with consistent quality.
  • High Tolerance Levels: Dental plates need to fit perfectly to function correctly. Nifty Bar’s Double-Disc grinding process ensures high tolerance levels, reducing the need for adjustments during surgery.
  • Enhanced Aesthetics and Functionality: With precise grinding techniques, the dental plates not only perform well but also meet the aesthetic demands of modern dental procedures.

Double-Disc Grinding: The Optimal Choice

Double-Disc grinding stands out as the optimal method for producing orthopedic and dental plates due to several advantages:

Efficiency: This method allows for the simultaneous grinding of two sides of the material, significantly reducing production time and increasing throughput.

Precision: Double-Disc grinding delivers unparalleled accuracy and uniformity, which is crucial for the intricate demands of medical components.

Cost-Effectiveness: By enhancing efficiency and reducing waste, Double-Disc grinding lowers overall production costs, providing economic benefits without compromising quality.

Versatility: This process is adaptable to a variety of materials and thicknesses, making it suitable for the diverse needs of medical manufacturing.


By choosing Nifty Bar, medical manufacturers can be confident in the integrity and effectiveness of their critical components. This ultimately contributes to better patient outcomes and advancing the field of medical technology.


Double Disc Grinding: A Precision Game Changer

Double Disc Grinding: A Precision Game Changer

In the realm of metal fabrication and part manufacturing, achieving precision, efficiency, and consistency in finishing processes is crucial. Among the various techniques at the disposal of engineers and manufacturers, Double Disc Grinding stands out as a superior method, particularly for flat surfaces. This grinding process offers numerous benefits, from high production rates to excellent dimensional accuracy, making it a preferred choice in various industries including automotive, aerospace, and general manufacturing.

Exceptional Precision and Consistency

Double Disc Grinding involves the use of two abrasive discs that remove material from both sides of a part simultaneously. This simultaneous action not only speeds up the manufacturing process but also enhances the consistency and uniformity of the part’s thickness. The process can achieve tolerances as tight as 0.0002 inches, which is crucial for high-precision components in critical applications. The consistency of this method helps in reducing the variability found in other grinding methods, leading to higher quality parts and fewer rejections in quality control checks

High Production Efficiency

One of the standout features of Double Disc Grinding is its capability to handle high volumes of parts in a relatively short amount of time. This method is designed for both single-pass and through-feed grinding, making it versatile for different production needs. Through-feed grinding, for example, allows continuous processing of parts, which is ideal for long production runs. The efficiency of Double Disc Grinding is particularly beneficial in industries where time and production volume are critical factors, contributing to faster turnaround times and increased throughput.


In addition to the high precision and efficiency it offers, Double Disc Grinding is a cost-effective manufacturing process. The initial setup and tooling costs are quickly offset by the speed and volume at which parts can be processed. Moreover, the durability of the grinding discs and the reduced need for secondary finishing processes make it an economical choice for manufacturers looking to minimize overall production costs. By reducing the cycle time and labor involved in the finishing process, companies can achieve a better return on investment.

Versatility Across Materials

Double Disc Grinding is not limited to a specific type of material, making it a versatile option for manufacturers working with a wide range of metals and composites. Whether it’s steel, aluminum, brass, or another alloy, the process remains effective and efficient. This adaptability extends to different sizes and shapes of materials, although it is especially renowned for its effectiveness with flat and parallel surfaces.

Improved Surface Finishes

The quality of surface finishes achievable with Double Disc Grinding is another significant advantage. The process can produce smooth surfaces that are often ready for use in final assembly without further treatment. This not only saves additional processing time but also ensures that components meet strict surface finish requirements commonly seen in automotive and aerospace applications.


Double Disc Grinding offers a combination of precision, efficiency, and cost-effectiveness that is hard to match with other metal finishing processes. It stands as a cornerstone technique in modern manufacturing, capable of meeting the demanding needs of various industries for high-quality, consistent, and economically viable component production. Embracing this technology can lead to significant competitive advantages, underscoring its importance in today’s manufacturing landscape.


Before (right) and after (left) of Double Disc ground parts by Nifty Bar.

The Basics of Double Disc Grinding

The Basics of Double Disc Grinding

Double Disc grinding simultaneously grinds two sides of material using two opposing abrasive wheels. It is a very effective grinding technique for obtaining surface smoothness, flatness, and parallelism with tight tolerances in the appropriate applications.

This grinding technique can remove more material, cutting the grinding time in half. Additionally, this method can efficiently process various materials — including stainless steel, tool steels, sintered metals, high-strength alloys, ferrous or non-ferrous metals, bronze, copper, aluminum, and more.

What Is Double Disc Grinding?

Double Disc grinding is typically employed for high-productivity manufacturing requirements. However, many factors may affect the output rates, including the size, material, stock removal,starting flatness, and tooling arrangement. Depending on these factors, outputs can be as high as 40,000 parts per hour or just a few pieces.

This technique is very effective and can cut pre-machining costs by as much as 50% since the material is removed from both sides in equal amounts in a single operation. It is ideal for requirements under the following conditions:

  • The parts have equal surface area requirements on opposing surfaces.
  • The size of the component required is close to the size of the grinding wheels.
  • The length, diameter, and overall width should be within tight tolerances.
  • The part’s thickness should be related to the opposing face to be processed.

Advantages of Double Disc Grinding

Depending upon the material and start flatness high dimensional accuracy can be obtained via Double Disc grinding, with tolerances, parallelism, and flatness down to 0.0005 inches (0.0127 mm). Controlling the thickness of small metal pieces using it is also economical.

Double Disc grinding can also improve your parts manufacturing processes in the following ways:

Reduced Machine Cost

Because the grinding wheels degrade throughout the conventional grinding process, they occasionally need to be changed or redressed. On the other hand, double disc grinding lowers the wear rate, resulting in fewer grinding process redressing stops.

High Degree of Accuracy

The ability to simultaneously grind both sides of the workpiece gives operators more control, allowing them to achieve tighter tolerances for flatness and parallelism checks. Additionally, when grinding aluminum, the method may produce surface polishes as high as 16 Ra and dimensional tolerances of 0.0005 in. Flatness tests can also achieve the same degree of precision.

Internal Stress Relief

Double Disc grinding lessens the workpiece’s residual load due to how it operates. During secondary operations and final machining, stability is improved when residual stress is decreased.

Better Surface Finishes

This technique can attain flatness tolerances that would be extremely challenging to achieve using a single-sided grinding procedure. In addition, Double Disc grinding generates a better surface polish than many other grinding procedures by lowering or removing grind patterns as pieces depart.

Double Disc Grinding With Nifty Bar

Materials processed through double disc grinding can be used to manufacture several products and applications, including the following:

  • Knives, handles, and clips
  • Component part blanks
  • Connecting rods
  • Cutters and dies
  • Extrusions
  • Gages
  • Gears and gear blanks
  • Laminations
  • Medical, dental, and orthopedic plates
  • Shims, spacers, and washers
  • Stampings
  • Substrates
  • Valve plates

Nifty Bar’s double-disc grinding technology offers precisely controlled processes creating superior surface finishes. We cater even to the most difficult-to-grind materials, such as titanium, Inconel, and a wide array of metal parts. Backed by our team of grinder experts, our mission is to meet our customer’s requirements with precision and quality.

Contact us to book an appointment or to request a quote. We look forward to working with you!