Precision machining and engineering support for complex extremity and spinal implants.
RevZero. Real-World Ready.
Orthopedic programs move fast. The details matter.
Plates, screws, and spacers are tight-tolerance components with high inspection requirements. When manufacturability and inspection strategy aren’t aligned early, the impact shows up later: revision churn, schedule slips, and “why didn’t we catch this sooner?”
RevZero brings DFM forward at Rev. 0 — so your first build isn’t your first surprise.
Where We Focus
RevZero specializes in machined orthopedic implants for extremities, trauma, and spinal applications. Our work centers on plates, screws, rods, and spacers where geometry, surface finish, and repeatability directly affect performance.
Extremities
and Trauma
Plates and screws for complex fixation systems.
Spinal
Applications
Spacers, plates, screws, and rods for fusion and stabilization.
Other Medical
Devices
Select precision components for regulated medical applications.
Extremities & Trauma Specialties
Precision components for complex anatomies
Extremity and trauma implants often combine small footprints, contoured surfaces, and demanding load paths. Design changes and SKU growth can create pressure across an entire implant family. RevZero supports extremity OEMs with controlled machining processes, consistent surface finishes, and repeatable results across left and right configurations and multiple size ranges.
What We Support in Extremities and Trauma
- Implant families with multiple sizes and mirrored versions
- Complex plate geometries for upper and lower extremity
- Controlled flatness, profile accuracy, and hole positioning
- Small, high-precision screws and fixation hardware
Foot & Ankle Fixation
Anatomically contoured plates and screws for forefoot, midfoot, and hindfoot constructs. We focus on profile accuracy, clean countersinks, and edge conditions that support soft tissue compatibility. Feature-to-feature relationships are maintained across size ranges.
Distal Radius Systems
Low-profile plates with complex hole patterns and variable angles. Machining and inspection methods are designed to maintain flatness and smooth contour transitions in thin sections. Attention to hole and slot geometry supports locking and angulation requirements.
Ulnar Fixation Implants
Long, narrow plates where distortion must be controlled during machining and finishing. Fixturing and sequencing are designed to reduce bowing and maintain consistent hole spacing. We support multiple lengths and curvature options within a single system.
Humeral Plates and Screws
Larger constructs with complex curvature and changing cross-sections. Multi-axis machining improves feature alignment and reduces handling. Programs scale from early trauma sets to sustained production with consistent dimensional results.
Tibial Fixation Constructs
Long plates requiring straightness and flatness over extended lengths. Controlled drilling and slotting sequences protect structural integrity. Inspection methods verify performance-critical dimensions and relationships.
Clavicle Plates
Highly contoured plates designed to match complex anatomy. Tight control of transitions and radii supports predictable fit. Finishing focuses on smooth edges and surgeon handling.
Olecranon and Elbow Fixation
Implants with pronounced curvature and concentrated loads near joint regions. Machining and finishing maintain geometry at screw interfaces and critical surfaces. Repeatability is maintained across size and offset variations.
Calcaneus Plates
Complex three-dimensional surfaces that require precise tool access and workholding. Sequencing maintains profile and hole locations through machining and finishing. Inspection verifies contour and datum relationships.
Metatarsal Plating Systems
Small plates and screws where minor dimensional shifts can affect performance. Stable processes support high-mix production common in metatarsal fixation. Control plans protect dimensional integrity during changeovers.
Spinal Specialties
Controlled manufacturing for load-bearing systems
Spinal systems introduce higher mechanical loads, tighter interfaces, and more complex assemblies. Small shifts in thread form, surface condition, or fit can affect performance and regulatory confidence. RevZero manufactures spinal implants and components with consistent dimensional control and defined inspection strategies from development through production.
What We Support in Spinal Programs
- Plates, spacers, rods, and screws for cervical and thoracolumbar systems
- Controlled thread integrity and mating geometries
- Component families across anterior, posterior, and lateral approaches
Expandable Interbody Spacers
Machining of spacer bodies and internal mechanisms to controlled clearances. Focus on alignment of moving components and consistent expansion behavior. Inspection plans target critical features such as ramps and locking elements.
Spinal Plates
Low-profile plates with complex curvature and screw interfaces. Machining maintains profile accuracy, hole angles, and countersink geometry. Finishing emphasizes clean seating surfaces.
Screws and Rods
Precision thread forms and tip geometries for pedicle and cortical screws. Controlled rod diameters and curvature where specified. Operations are structured to maintain concentricity and straightness.
Anterior, Posterior, and Lateral Fusion Systems
Support for complementary plates, spacers, screws, and rods used across surgical approaches. Emphasis on consistent interfaces so components mate correctly across sets and sizes.
Sacroiliac Joint Compression Screws
Long, large-diameter screws requiring tight control of runout and thread form. Processes manage chip evacuation and surface condition in deep features. Inspection focuses on pitch, diameters, and straightness.
Pedicle Screws
Control of critical diameters, thread profiles, and drive features. Processes maintain clean threads and defined radii. Verification methods align with your validation and risk documentation.
Other Medical Device Applications
Precision components for complex anatomies
While our primary focus is orthopedic implants, the same machining and quality systems support other regulated device components. When a design requires tight tolerances, complex geometry, and documented process control, we evaluate fit within our capabilities. This includes select minimally invasive instruments and precision-machined components for Class II and Class III devices.
- Precision components for minimally invasive or trauma instruments
- Complex subcomponents requiring full traceability
- Bridge and pilot production for new device introductions
The RevZero Difference
Orthopedic manufacturing is not just about machining. It is about alignment between design, inspection, and long-term production.
Design‑for‑Manufacturability and Process Planning
- Review of tolerance stack-ups and inspection feasibility
- Feedback on features that drive risk or unnecessary cost
- Early alignment on validation and control strategy
Precision Machining for Complex Geometries
- Multi-axis machining and Swiss turning for contoured implants
- Stable workholding for thin or elongated parts
- Controlled sequencing for drilling, tapping, and slotting
Quality Systems and Traceability
- ISO 13485:2016 certified QMS and FDA-registered facility
- Material control and in-process verification
- Inspection documentation aligned to your drawings
Orthopedic Specialties Frequently Asked Questions
Yes. RevZero supports early-stage orthopedic product development by providing manufacturability feedback during design, helping engineering teams identify risks and confirm a stable path to production before designs are finalized.
Yes. RevZero supports both trauma and spinal programs. Trauma components often involve complex geometries and thin profiles, while spinal devices require consistent material integrity and repeatable process control. Our manufacturing approach is structured to support both application types from prototype through production.
RevZero manufactures components used in spinal systems such as interbody spacers, spinal plates, pedicle screws, rods, fusion systems, and sacroiliac joint compression screws. Each program is supported with application-appropriate inspection, documentation, and process controls.
Thread integrity is critical for fixation performance. We use stable turning processes and defined inspection methods to verify pitch, major and minor diameters, concentricity, and surface condition. For longer screws, we also monitor runout and straightness to ensure reliable engagement and load transfer.
Yes. RevZero manufactures precision components for minimally invasive orthopedic devices where small features, tight tolerances, and surface finish are critical. These programs often benefit from early DFM input to reduce iteration and stabilize designs before scale-up.
Ready to Start at Rev. 0?
Whether you are refining an existing implant or starting from an early concept, our team will review your drawings, timeline, and quality expectations and recommend a clear manufacturing path.