Application of the Week: Custom Ergonomic Wrench

Welcome to our application spotlight series, where we showcase real-world 3D-printed solutions that solve industrial challenges. Each featured part demonstrates how 3D printing can reduce costs, accelerate lead times, and unlock new design possibilities.

In this article, we’re highlighting a customized maintenance wrench, an essential tool on many packaging lines.

Designed by Heineken Sevilla with operator comfort in mind, this 3D-printed wrench is built for demanding use and demonstrates how additive manufacturing can deliver smart, cost-effective upgrades to even the most familiar tools.

Reengineering a shop floor essential

Maintenance crews on packaging lines regularly use heavy-duty wrenches to tighten or loosen large nuts during equipment servicing. Traditionally made from stainless steel, these tools are durable but expensive, with long lead times. More importantly, they’re rarely optimized for user comfort or tailored to the specific needs of individual machines.

By leveraging 3D printing, this ergonomic wrench was redesigned to improve grip, reduce operator fatigue, and dramatically lower production costs—all while maintaining the strength needed for demanding tasks, such as loosening and tightening the capping module of the packaging machine. It also features the ability to slide on different shaped grips - big, small, or fully customized - making it adaptable to various user needs and enhancing comfort even further.

Resources saved

Thanks to 3D printing, Heineken Sevilla could spare both time and money compared to traditional manufacturing methods. With in-house 3D printing, companies can react fast when a spare part or tool is needed, minimizing any downtime.

Traditional manufacturing

• Material: Stainless steel
• Lead time: 2 weeks
• Cost: ~€600

3D printing with UltiMaker

• Material: UltiMaker CPE + TPU 95A
• Time: Less than 1 week
• Cost: €20
• Cost saving: 97%

Key features and benefits

Let's take a look at some of the key features and benefits of using additive manufacturing for this application.

Ergonomic design for improved comfort

This wrench includes built-in ergonomic enhancements to reduce strain during use. The handle is shaped to fit comfortably in the user’s hand and can be further customized to individual preferences or tasks.

Dual-material construction

The tool combines a stiff engineering material for structural strength with UltiMaker TPU 95A on the handles. TPU 95A is a flexible, rubber-like material that enhances grip and comfort, especially during repetitive tasks or long maintenance shifts. With UltiMaker Cura, you have the possibility to further improve the wrench by using settings such as fuzzy skin option to create a better grip.

Fully customizable and fast to produce

Thanks to 3D printing, every detail - from size and shape to color-coding and labeling - can be easily adjusted to meet unique needs. Producing the wrench in-house also means rapid iteration and faster delivery to the shop floor.

Enhance operations with UltiMaker

This application demonstrates how 3D printing doesn’t just replace traditional manufacturing - it enhances it. By redesigning a common maintenance tool with operator needs in mind, manufacturers can improve workplace ergonomics, reduce costs, and gain greater control over production timelines.

Looking to optimize your operations with custom tooling or line-side solutions? Discover how UltiMaker’s 3D printing ecosystem can help streamline your workflow and keep your factory floor moving.