Stingray Surgical Products: Leading the Way in Nimble Electrosurgical Manufacturing

Stingray Surgical Products, based in Boca Raton, Florida, is a niche leader in electrosurgical device design and manufacturing. Their specialty—bipolar forceps, or “electrified tweezers” that simultaneously cut and coagulate tissue—sets them apart in a U.S. market with few competitors.

Using Swiss‑type turning technology, Stingray produces these precision instruments with unparalleled efficiency. Source: Stingray Surgical Products

Business development manager Shaun Mymudes of Roboris/Eureka—known for NC Coder programming and simulation software—first introduced me to Stingray. President Brian McBrinn emphasized the advantage of being a focused manufacturer: “We’re not a multinational; we can move fast. When you call us, you talk to someone who knows what they’re doing. With larger competitors, you’re stuck in phone tag for answers. We pivot immediately to meet a customer’s need—that’s where we win.”

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Stingray’s roots trace back to 1986, when Brian’s father, Mark, founded Mark Medical Mfg. in Pennsylvania. After years of experience in medical device repair, Mark expanded into gynecological instrumentation, later bringing his wife Diana on board in 1989. In 2006, the family launched Stingray Surgical Products to focus on electrosurgical instruments, accessories, and repair services.

Many parts are tiny—like the screws used in forceps—requiring the Nomura DS NN 20J3 Swiss‑type lathe, which can machine uncommon thread pitches. Source: PM

Brian McBrinn joined the company in high school. In 2023, he and sister Stephanie Moran took over, prioritizing CNC technology and automation. Swiss‑type lathes replaced earlier molded‑part processes, offering flexibility for rapid design changes. Although the initial Swiss‑type was not the most versatile, acquiring a Nomura DS in 2016 provided the needed adaptability. In late 2024, it was upgraded again, and paired with Eureka’s NC Coder for advanced programming and simulation.

Stingray runs its Swiss‑type lathe unattended overnight when possible, leveraging a built‑in camera for remote monitoring. This practice is crucial for a small operation with eight employees.

New Swiss‑Type, Software

Batch sizes are modest: PEEK parts rarely exceed 500 units, stainless steel up to 2,000, and some parts as few as 100. Job changeover speed is therefore critical. The Nomura DS offers an open workzone for quick tool changes, an offline tool presetter, a standard chip conveyor, and Micro Vibration Turning (MVT) technology that reduces cutting forces and extends tool life. The Mitsubishi M 80 CNC allows multichannel programming, and Wi‑Fi transfer of part programs streamlines workflow.

Previously, a pin connector on bipolar forceps required purchasing round bar and manual grinding. Now, it’s machined in one piece on the Swiss‑type lathe and laser‑welded to the forceps blanks. The machine also produces small screws with atypical thread pitches.

Programming and Simulation Software

Historically, Stingray relied on Fusion 360 or handwritten G‑code, which left room for costly errors in micro‑components. Eureka NC Coder from Roboris now enables the import of multiple tool paths, channel assignment, and full simulation before the machine runs. “The simulation matches what happens on the machine,” McBrinn says. Benefits include fewer revisions—often dropping from 10 to 1–2—and greater confidence without constant machine‑to‑code back‑and‑forth.

To expedite changeovers, a Miruc Measure Scope sets X, Y, and Z tool positions offline. Source: PM

Eureka NC Coder works with popular CAM systems, generating G‑code via a machine‑specific postprocessor and validating the entire program in a digital‑twin simulation. Younger staff familiar with Fusion 360 find the transition smooth, eliminating the need to learn an entirely new CAM system.

Stingray boasts comprehensive in‑house capabilities: laser marking, welding, epoxy, powder coating, and a bipolar forceps testing machine to verify insulation performance.

Next Steps

Late last year, the company added a Nomura DS drill/tap machine with a dual‑contact BT‑30 spindle interface and 28‑tool ATC, enabling in‑house production of bipolar forceps from 400 series stainless steel billets. McBrinn plans to automate this process with a spindle gripper and extend NC Coder simulation to the new machine.

By consolidating production processes, Stingray reduces dependency on external vendors and enhances agility to meet evolving customer demands. Their focus on advanced manufacturing technology and real‑time simulation positions them as a trusted partner in the electrosurgical market.