3D printing jigs and fixtures: Revolutionizing manufacturing efficiency

3D printing has revolutionized manufacturing processes, offering versatile solutions that enhance efficiency and precision. Among these advancements, 3D printed jigs and fixtures stand out as transformative tools.

These custom-designed components are rapidly replacing traditional manufacturing methods, providing significant improvements in production speed, cost-effectiveness, and overall quality. As industries increasingly adopt additive manufacturing, understanding the capabilities and benefits of 3D printing jigs and fixtures becomes crucial for staying competitive and optimizing manufacturing workflows.

This article explores the applications, materials, design considerations, and future trends of 3D printed jigs and fixtures, illustrating their profound impact on modern manufacturing.

Understanding 3D printed jigs and fixtures

3D printed jigs and fixtures are changing manufacturing by providing a quicker, more economical alternative to traditional methods. These custom tools improve production efficiency, accuracy, and safety across industries.

Jigs are tools that guide cutting or machining tools during manufacturing. They ensure accurate operations, such as drilling holes or shaping components, with high repeatability. Fixtures hold workpieces in place for tasks like welding, assembly, or inspection.

Key advantages include reduced lead times, lower costs, rapid prototyping, customization, and the ability to create complex geometries. These benefits have led to adoption in industries such as automotive, electronics, and construction.

For instance, automakers have reported significant savings in cost and time by using 3D printed assembly tools. As the technology advances, the potential for jigs and fixtures expands, moving beyond prototyping to become an integral part of manufacturing. The next section will discuss in detail the benefits of using 3D printed jigs and fixtures in manufacturing.

Benefits of 3D printed jigs and fixtures in manufacturing

Using 3D printing for jigs and fixtures offers many advantages for manufacturers aiming to improve their production. One significant benefit is the reduction in lead times. Tools can go from CAD file to finished product in hours or days, which greatly shortens production timelines.

Cost savings are another major advantage. With no minimum order quantities or expensive tooling needed, even single prototypes become affordable. Printing on demand also removes inventory costs, further cutting expenses for manufacturers.

The ability to quickly prototype and change designs is a key advantage. Design changes are simple file edits and reprints, allowing for quick improvements. This flexibility extends to customization, as jigs can be tailored for unique components or processes. It's also useful to produce tools for rare, obsolete, or one-of-a-kind parts.

Complex geometries that are hard to achieve with traditional machining become feasible. This enables good part alignment and faster integration in manufacturing.

Beyond cost and time savings, 3D printed jigs and fixtures can improve ergonomics for workers. Lightweight designs reduce fatigue, and customized tools can be optimized for specific tasks and body mechanics, enhancing comfort and productivity. The versatility of these tools leads to their wide use in several applications, as the next section will show.

Applications of 3D printed jigs and fixtures

3D printed jigs and fixtures are transforming manufacturing processes across various industries. The automotive industry has been particularly quick to adopt this technology, with major manufacturers reporting significant improvements in efficiency and cost savings.

Volkswagen Autoeuropa, Portugal's largest automotive plant, revolutionized their manufacturing process by bringing jig and fixture production in-house using Ultimaker 3D printers. The results were remarkable: time savings of 89% and cost reductions of 98%. Within the first two years of implementation, Volkswagen Autoeuropa saved approximately €475,000 ($525,000) by replacing externally manufactured tools with in-house 3D printed alternatives. One specific example is a liftgate badge positioning tool that previously cost €400 with a 35-day lead time from external suppliers but now costs just €10 and can be produced in only four days.

Ford's pilot plant in Cologne, Germany has established a dedicated 3D printing workshop to manufacture custom tools, jigs, and fixtures. After initially experimenting with SLS technology, Ford engineers switched to Ultimaker FFF printersfor their faster turnaround times and lower post-processing requirements. Their team now saves more than 50% on manufacturing costs while cutting lead times by more than half. An innovative example is their custom hook-on jig for the rear of vehicles, printed in Tough PLA (as strong as ABS but soft enough to prevent bodywork scratches), which enables quick and precise positioning of badges and emblems, resulting in fewer deviations.

In electronics manufacturing, 3D printed jigs offer particular advantages for PCB production. Custom fixtures can securely hold components during soldering processes, ensure alignment of stencils for precise solder paste application, and create standardized testing setups. These applications are especially valuable for small-scale production and prototyping, where traditional metal fixtures would be prohibitively expensive.

Industrial service providers like ERIKS have integrated Ultimaker 3D printers to improve their production processes. One notable application at ERIKS is a box drilling jig with press-fit metal tube inserts that enables precise, repeatable hole drilling. This jig includes magnetic inserts that snap onto a metal vice, providing stability during the drilling process. Another example is their motor assembly jig, which perfectly supports a motor during the addition of electronic components, reducing assembly time from 2-3 minutes to just 1 minute.

Jabil, a global manufacturing services company, implemented Ultimaker 3D printers at their Auburn Hills facility and reported an 80% reduction in delivery time and 30-40% cost reduction for tooling components. The company found immediate success with the technology, receiving an order to print spare parts just three hours after installing their first Ultimaker machine. For Jabil, the elimination of minimum quantity requirements and ability to produce one-off items without cost constraints has been transformative.

Even Ultimaker itself practices what it preaches, using their own 3D printers to create tools, jigs, and fixtures for their manufacturing facility. One example is a custom-designed pressure fixture that assists in the assembly of sliding blocks for their 3D printers. This fixture is printed using XSTRAND™ GF30 PA6 (nylon with 30% glass fiber) for extreme strength, combined with Ultimaker TPU 95A (a flexible material) to prevent damage to the sliding blocks during assembly.

Materials for 3D printing jigs and fixtures

Selecting the right materials is important for creating effective 3D printed jigs and fixtures that can withstand manufacturing environments. Several materials are excellent options for producing durable, functional tooling.

For general-purpose jigs and fixtures, Tough PLA offers an excellent balance of strength and usability. This material is as strong as ABS but soft enough to prevent scratches on finished parts, making it ideal for applications like Ford's badge positioning tools where contact with finished surfaces is necessary.

When higher strength is required, composite materials like XSTRAND™ GF30 PA6 (nylon with 30% glass fiber) provide excellent rigidity and durability. Ultimaker uses this material for their own manufacturing fixtures that need to withstand repeated use and mechanical stress. For fixtures requiring compliance or cushioning, this can be combined with flexible materials like Ultimaker TPU 95A to create multi-material tools that protect workpieces.

For applications requiring chemical resistance or higher temperature tolerance, engineering-grade materials such as Ultimaker ABS, CPE, or nylon variants are recommended. These materials can withstand exposure to common industrial chemicals and maintain their structural integrity in warmer environments.

Specialized tools often benefit from material combinations. Volkswagen Autoeuropa's wheelgun jig, which guides their wheelgun into wheel nuts without scratching the rim, demonstrates how material properties can be optimized for specific applications. This approach prevents damage to finished products while ensuring precise tool positioning.

Design considerations for 3D printed jigs and fixtures

When designing 3D printed jigs and fixtures, several factors must be considered to ensure performance and functionality. Material selection is important, with options ranging from ABS for strength in low-heat applications to PEEK for high-temperature environments.

Structural integrity is needed to ensure the fixture can withstand forces. Design with wall thicknesses, reinforcement ribs for added strength, and consider the part orientation during printing to optimize strength.

Ergonomics and user interface design are essential for worker comfort and efficiency. Design handles for comfortable use, optimize weight distribution to reduce fatigue, and use visual cues for ease of use.

Modularity and adaptability in design allow for flexibility. Create interchangeable components for different product variants, adjustable features to accommodate size variations, and parts that can be modified and reprinted as needed.

Integration with existing systems is important for implementation. Design jigs to fit machinery or workstations, consider interface points with other tools, and incorporate mounting features.

Post-processing should also be considered in the design. Minimize support material, plan for surface finish treatments, and incorporate features to aid in assembly if the jig consists of multiple printed parts. As technology evolves, several future trends are set to shape the landscape of 3D printed jigs and fixtures.**

Future trends in 3D printing jigs and fixtures

The future of 3D printed jigs and fixtures is being shaped by several emerging trends that promise to further enhance their utility in manufacturing environments.

Integration with Industry 4.0 concepts is creating more connected manufacturing environments. Luis Rodriguez, Application Engineer at UltiMaker, notes that while there has been "tremendous progress towards printing tooling, jigs and fixtures," there remains "a huge opportunity" for companies to discover 3D printing as "a viable alternative to traditional manufacturing."

User-friendly design tools are making jig and fixture creation more accessible. Trinckle's generative software solution, used by Ford and ERIKS, allows workers without 3D printing experience to generate custom jigs. This democratization of design capabilities enables production staff to develop and refine their own tools, improving aspects like ergonomics and functionality based on direct experience.

The data from Jabil suggests a clear trend: in 2021, 57% of companies reported using 3D printing for tooling, jigs, and fixtures, up from just 30% in 2017. This growing adoption indicates that 3D printed manufacturing aids are becoming mainstream, with industry leaders predicting that eventually "all fixtures and jigs will be 3D printed."

Sustainability considerations are also driving innovation in this space. Companies are increasingly viewing 3D printed jigs and fixtures as environmentally friendly alternatives to traditional metal tooling. By producing only what is needed when it's needed, and by extending the lifespan of existing equipment through custom accessories, manufacturers can reduce material waste and energy consumption.

Evolving manufacturing with 3D printed jigs and fixtures

The integration of 3D printing into manufacturing through jigs and fixtures signifies a shift towards more agile and efficient production processes. This adaptability not only reduces costs and lead times but also enhances the overall quality and precision of manufacturing operations. Companies like Volkswagen Autoeuropa, Ford, Jabil, and ERIKS have demonstrated the transformative impact of Ultimaker's 3D printing solutions, achieving remarkable cost savings (up to 98%) and time reductions (up to 89%) compared to traditional methods.

As UltiMaker's Application Engineer Luis Rodriguez observes, successful implementation requires organizational commitment: "If a company doesn't commit a person to focus on this a few hours a week then adoption will never happen." However, for those who make this commitment, the rewards are substantial. The ability to produce custom tools on-demand, iterate designs quickly, and optimize for specific production challenges provides a competitive advantage in today's fast-paced manufacturing environment.

By embracing these advancements, manufacturers can stay competitive, optimize workflows, and meet the dynamic demands of modern industries, ensuring a future where production is both streamlined and sustainable. The growing adoption of 3D printed jigs and fixtures, from 30% of companies in 2017 to 57% in 2021, suggests that this approach is increasingly becoming standard practice rather than just an innovative exception.