Using Additive Manufacturing for Production Jigs and Fixtures

What jigs and fixtures do

A jig helps guide a tool or operation. A fixture locates and holds a workpiece. In practice, teams also use the terms for gauges, nests, templates, protective covers, alignment aids and ergonomic shop-floor tools.

The value comes from reducing variation or making a task clearer—not from the complexity of the printed object itself.

• Drill or marking guides
• Assembly alignment nests
• Inspection and go/no-go gauges
• Sensor or camera mounts
• Protective caps and guards
• Part trays and handling aids
• Soft jaws and workholding inserts

Why additive manufacturing fits production tooling

Traditional tooling methods remain appropriate for high loads, precision datums and long service life. Additive manufacturing adds another option when the tool is specialized, needed quickly or likely to change after operators use it.

Complex contours, labels, ergonomic grips and lightweight internal structure can be incorporated without conventional tooling. A digital file also makes revised or replacement copies easier to produce.

Look for repeatable operational value

A useful jig can pay for itself by preventing rework, simplifying training, reducing handling time or improving operator comfort. The business case should be based on the operation it improves rather than comparing the printed tool only with the price of raw material.

Start with a repetitive task that has visible variation or frustration. Observe the actual workstation and involve the people performing the work before finalizing geometry.

Design considerations for a shop-floor tool

• Define locating surfaces and datums
• Keep the load path clear and supported
• Use generous radii around stressed transitions
• Allow access for hands, tools and fasteners
• Avoid trapping debris or process fluids
• Make wear surfaces replaceable where practical
• Use colour or geometry to prevent incorrect loading
• Include identification and revision control

Select material around the workstation

A light-duty inspection template in a controlled room has different needs from a fixture beside warm machinery. Consider stiffness, impact, sustained clamping load, temperature, oils, cleaners, moisture and ultraviolet exposure.

The printed polymer may also need threaded inserts, metal bushings, pads or standard hardware at high-wear interfaces. Hybrid construction often provides a practical balance between rapid custom geometry and durable contact points.

A practical development workflow

1. ObserveDocument the current task, failure modes, cycle and operator constraints.
2. DefineIdentify what the aid must locate, guide, protect or verify.
3. PrototypeProduce a low-risk version and test access, fit and sequence.
4. ValidateEvaluate repeatability, loads, wear and misuse under real conditions.
5. ReviseIncorporate operator feedback and control the file revision.
6. DeployDocument inspection, replacement and training requirements.

Information to include with an RFQ

• Production-ready STL
• Workpiece dimensions or reference model
• Required quantity
• Expected loads and cycle count
• Temperature and chemical environment
• Critical locating surfaces
• Hardware or insert requirements
• Desired delivery date