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3D Printed Jigs and Fixtures Can Help Boost your Productivity

Liuzhou JingDa Automotive Brake Tube Manufacturing Co., is a leading supplier for SAIC Motor for break tubes for both Micro and Passenger cars. Mr. Bian, the technical director of JingDa, says that 3D printing is certainly having a tangible impact on how break tube engineers create solutions that improve the effectiveness of production lines while enhancing the effectiveness of the tubes.

Everything JingDa does with 3D printing revolves around aiding in one or more of three benefits: quality, productivity, and increased effectiveness. In fact, those pillars are arguably at the core of any factory around the world.

Here’s a look at JingDa Automotive’s brake tubes. There are 6 sorts of brake tubes, at least, required on every single vehicle, some require 8 kinds or more. Each and every tube needs test fixtures to measure them to see if they’re in spec.

Traditional brake tube fixture

 Traditional fixtures can’t test these tubes quickly enough. They also can’t test them accurately according to the key position and the tortuosity of the brake tubes. The quality and the precision that FDM 3D printing brings to the table can satisfy the conditions required.

Traditional brake tube fixture

In order to complete a whole project in one week, the company will need 2 sets of 3 meter long fixtures to inspect a fixture line. To complete this task Jingda reached out to Deed 3d printing company. With more than 40 Stratasys Fortus printers, Deed3D have very short turnover time. Indeed the delivery of the fixtures was completed within 5 days.

ABS-M30 material printed on Stratasys 900MC printers, 500mm to 800mm length model.

Comparison between CNC and 3d printing fixtures

mode of production

Original CNC Production

Stratasys FDM 3D Printing

Production Method

After each independent inspection fixture is completed, all inspection fixtures are fixed on the substrate by means of bonding.

Print in one piece, or print in sections, and then fix it on the substrate.

Cost

The cost of the two methods of production is not very different

Time

The production time is long, it is difficult to control the delivery period, and it will affect the project progress.

The turnaround time is short and controllable. It can be controlled according to its own production schedule without affecting the project schedule.

Production difficulty

The more curved detection parts will make the production of the inspection fixture difficult and the accuracy difficult to control.

The degree of bending of the product has nothing to do with manufacturing difficulty, and the accuracy is easy to control.

Accuracy

Low accuracy caused by splicing fixture

Accuracy is much higher than the customer requirement

Data requirements

2D projection + height marking

3D data, need to redraw

Convenience

Heavyweight solid material, inconvenient to use

Sparse printing, lightweight, easy to use

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How 3D Printing Jigs and Fixtures Transforms Manufacturing Part II – All About Fixtures

Fixtures are essential for custom manufacturers. Fixtures hold the workpiece in place so it does not move during a step in manufacturing. Some shapes are easy to hold such as a rectangular block. For example, the part can be simply held in a vice. For shapes with various curves and angles, it can be difficult to hold them sturdy using standard tools. Fixtures solve this problem by clamping onto parts while matching the part’s geometry like a glove.

Jig or Fixture?

Fixtures may sometimes be called jigs, but they are not the same thing. Jigs guide the motion of tools and they are usually used in manual operations such as drilling holes. Fixtures are very sturdy and will accurately hold the workpiece at the correct angle, but fixtures do not guide tools. Fixtures are more often used with automated manufacturing methods. For more information on Jigs, check out our article about jigs.

All about Fixtures

Fixtures make inserting and removing parts much easier. They are typically designed in an intuitive way that reduces the risk of human error. Fixtures can be re-used for large production runs, or created specifically for a small number of custom parts.

Fixtures must be mounted to a sturdy surface before they can be used effectively. Some fixtures are designed to fit onto a standard bench vice, others attach to standard mounting boards like  T-slot tables or hole grids. Fixtures are rigidly bolted or mounted onto shop equipment.

Traditionally, custom fixtures are made manually. The design is planned out, then work material is cut, milled, and drilled into shape. This process requires costly materials, expensive equipment, skilled machinists, and a considerable amount of labor. It may also require purchasing new tooling for unique shapes.

Benefits of 3D Printed Fixtures

3D printing is a viable alternative when it comes to creating custom fixtures. It is more cost-effective to 3D print a custom fixture than it is to machine one in-house. With 3D printing, a fixture only needs to be designed using CAD software and sent out to a 3D printing service such as www.shapeways.com After a few days, it’ll get printed, shipped and delivered, ready to use.

3D printed fixtures are made from strong and lightweight plastics such as nylon. Nylon is tough and durable. Fixtures made from nylon will last for many production cycles. As a plastic, it is not as dense as metal, so large fixtures will be lightweight in comparison. Nylon is softer than most rigid materials, and this is good because the fixture will not scratch or damage the part’s surface. The softer material aids in providing a more uniform clamping pressure. Under high clamping loads, the nylon can deform to the shape of the part, saving both from being damaged.

Here are a few examples of innovative fixtures that have been designed specifically for 3D printing.

1”x1” Board Fixture

This fixture is mounted onto a 1”x1” mounting grid board or mounting table. It can be used to hold your working piece in place to either be cut, drilled or assembled. The working piece is clamped by the fixture as screws are tightened, holding it securely. This fixture can also be used as a cylinder holder for cutting pipes and tubes.

Material: Multi Jet Fusion Plastic – Gray PA12 (nylon 12)

Bench Vice Jaw Adapter Fixture

This fixture is an accessory for a bench vice that when attached, can hold a wide arrangement of objects. This is done by inserting magnets (not included) into the provided spots on the back of the fixture and then placing the fixture onto the jaws of a bench vice.

Material: SLS – PA11 (nylon 11)

Door Lock Installation Fixture

This is a fixture used to assist in the installation of a doorknob or lever. It provides accurate alignment between the working parts of a doorknob or lever. This is done by finding the centerline of your door edge, aligning the two smaller holes with the centerline and securing the fixture to the door with screws temporarily at those points. Once that is done, you can now use the recommended hole saw and the fixture as a guide to drill the remaining holes out where you would be left with perfectly aligned holes to install a doorknob or lever.

Material: Versatile Plastic – White Processed

Cut Down Your Production Costs

If you would like to learn more about how 3D printing can help your business save money and reduce manufacturing costs, get in contact with Shapeways using our Sign up form.

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How 3D Printing Jigs and Fixtures Transforms Manufacturing 

In the industrial world, 3D printed jigs and fixtures are truly unsung heroes. Both jigs and fixtures are types of tools that are used to control the operation of another instrument. However, a fixture sets itself apart in that it’s mainly used to hold another tool or device in place during the manufacturing process.

As a manufacturer, in any industry, you rely on essential components like jigs and fixtures to get the job done. The difference is that these days, more and more manufacturers are realizing massive productivity increases and lowered costs by 3D printing these essential manufacturing aids.

In this series of articles, we will layout the benefits of using additive manufacturing to produce Jigs & Fixtures. The first part will focus on Jigs. To find out more about how you can harness the potential of 3D printing jigs and fixtures to increase productivity and reduce costs, read on.

Jigs 101

Jigs are custom-made tools that hold in place and control the motion of other devices or parts in the manufacturing process. Unlike a fixture, a jig lets manufacturers expedite the assembly or construction of a product by allowing for greater interchangeability and repeatability.

It should come as no surprise, then, that jigs are a staple in virtually all mass-production systems in the developed world. However, small and medium-sized firms traditionally haven’t been able to create custom-made jigs until the arrival of 3D printing technologies.

Why 3D Print Jigs and Fixtures?

Most companies cannot afford to splurge on traditionally manufactured jigs and fixtures to add to their assembly lines or build processes. Thanks to the advent of additive manufacturing, productivity-enhancing tools such as jigs, fixtures, and grips can now be produced at a fraction of the cost of their traditionally made counterparts.

Producing jigs and fixtures via 3D printing is a highly cost-effective means of speeding up your assembly times and reducing labor costs. Plus, on-demand jig and fixture production eliminates upfront inventory requirements. Instead, digital inventory allows for seamless updates and revisions to keep your equipment working the way it should.

Other benefits of 3D printed jigs and fixtures include weight reduction (via high-strength plastic construction), ergonomic superiority (via customizable item contouring and shaping) and reducing overall complexity during the manufacturing process.

Here are examples of jigs that you can 3D print today:

Router Corner Jig

Built with black versatile plastic, a SLS nylon 12, this woodworking tool is designed to create precise cuts around angular corners during woodworking. A workshop essential, this 3D-printed tool allows users to make consistent cuts around edges when using a Router tool.

Cutting corners has never been easier thanks to this corner jig, which holds to the corner of your working piece to guide cuts at an exact and consistent radius.

Rotary Tool Drill Bit Sharpener Jig

Constructed with multi-jet fusion plastic, smooth black nylon 12, this rotary drill bit sharpener tool is the DIYers dream. This jig sharpens dull drill bits to their original condition by crafting a new cutting edge on the side of the tool. The process is simple: the jig attaches to a rotary tool and a grinding disc.
Then, the drill bit is inserted into the jig at the correct angle. The jig, in conjunction with the abrasive disc, proceeds to grind the drill bit to the user’s preferred degree of sharpness in seconds.

Center Point Finder Jig

This time-saving jig tool streamlines your assembly processes by allowing you to locate the midpoint of objects with varying levels of thickness. Made of durable red versatile plastic, a SLS nylon 12, the Center Point Finder Jig works according to a simple process: the jig is placed on top of an object that the user wants to measure, then the jig is twisted until the pegs cannot move any further. Then, the indicator in the center of the jig signifies where the midpoint of the object is.

Ready to Save Money for Your Company?

There has never been a better time to invest in jigs, fixtures, grips, and other tools that can save your company time and money when manufacturing. Typically, a jig or fixture would be sent away to be produced by a trained machinist for days at a time.

Today, 3D printing has cut down production times and created a more affordable alternative for manufacturers in need of custom-made assembly tools.

Interested in learning more about how 3D printing can impact your business by increasing productivity and lowering production costs? Get in touch today to learn how Shapeways, the leading end-to-end 3D printing fulfillment platform, is helping millions of companies leverage 3D printing to scale their businesses.

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