3D printing with Selective Laser Sintering (SLS) technology is an ideal solution for cost-effectively producing on-demand consumable parts, such as these collet pads, which serve as an interface between constantly changing workpieces and CNC lathes.
Machining fixtures and jigs are tools used in subtractive manufacturing processes, such as CNC machining, to ensure precise workpiece alignment and safe operation.
While a fixture is a workholding device used to hold metal workpieces or other materials in place during CNC milling or CNC turning, a jig guides the movement of the cutting tool, or milling tool. The jig can move along with the tool while maintaining its precise path.
Jigs are commonly found in small factories or workshops that may not yet have complex CNC systems and still rely on manual milling or turning. Milling jigs act as a failsafe and help reduce the likelihood of operator errors.
These tools, historically made from metal, wood, or plastic, are used daily to produce millions of parts through subtractive processes like CNC milling or turning, significantly impacting the efficiency of the manufacturing process.
With modern technologies like 3D printing and Computer-Aided Design (CAD), machining jigs and fixtures can be improved in many aspects, including cost reduction, customization for specific applications, material waste reduction, and many other benefits.
Introduction to Machining Fixtures and Jigs
What is Machining?
In the CNC turning process shown above, a lathe is used to rotate a cylindrical brass workpiece while a cutting tool moves linearly.
The machining fixtures used in the image are the silver metal blocks on the left, which act as workholding clamps to secure the workpiece firmly during the machining process.
Machining refers to all types of subtractive manufacturing processes where material is removed from a larger workpiece to achieve a desired shape.
Machining has been the primary method for creating specific shapes from raw materials such as wood, metal, ceramics, and other materials for hundreds of years. Although the term "machining" today often refers to industrial manufacturing processes, historically, similar processes were mostly manual carving or shaping.
There are various types of machining, each differing in how material is removed from the workpiece, as well as the type of tools used for cutting the material.
Main Types of Machining Operations
The above are just some of the types and subcategories of machining operations. Each type of machining can be classified by various factors, such as the method of material removal, the type of tool used, the rotation of the workpiece or tool, and other elements related to the cutting process.
- Milling: Uses a high-speed rotating cutting tool. During milling, the workpiece material is held stationary while the cutting tool moves around the workpiece to remove excess material until the desired shape is achieved.
- Turning: This method uses a stationary cutting tool to remove material from a rapidly rotating workpiece. CNC turning fixtures must therefore be able to securely hold the workpiece during high-speed rotation.
- Drilling: The most common machining process, used to create small holes (smaller than those made by boring). Drilling can be done both with machines and common household handheld drills.
- Boring: While many are familiar with "boring" in the context of drilling holes in the ground, in machining, boring is the process of creating or enlarging cylindrical holes within a workpiece, such as manufacturing gun barrels.
- Broaching: A broach tool has multiple cutting teeth arranged in sequence to gradually remove material from a workpiece until the desired shape is achieved. This is a primary process used in manufacturing gears. Linear broaching pushes the tool through the workpiece, while rotary broaching causes both the tool and the workpiece to rotate simultaneously, requiring a fixture to hold the workpiece securely.
- Grinding: Generally used as a finishing process rather than for removing large amounts of material. It is often a secondary step to improve the surface quality of previously machined workpieces.
- Reaming: Used to enlarge or refine pre-drilled holes, using a multi-flute tool to remove material inside the hole to achieve more precise dimensions and smoothness.
- Planing: Similar to woodworking planing, it uses a stationary cutting tool and moves the workpiece past the tool to cut material to the desired shape. Planing is suitable for creating flat and smooth surfaces, as well as dovetail joints and curved or concave surfaces.
- Sawing: An easily understood machining process that uses a cutting tool with saw teeth or serrated edges to separate or divide a workpiece into multiple parts.
- Waterjet Cutting: A machining process that uses a high-pressure water stream to separate or remove material from a workpiece.
- Burning Machining Methods: A group of machining processes that use intense heat to separate materials, such as plasma cutters, laser cutters, and oxy-fuel cutting, often used for applications requiring exceptionally high precision.
Machining Support Equipment: Fixtures and Jigs
This automotive part (the silver part in the middle) is being milled while held in place by a two-piece fixture (the dark gray parts on the left and right).
More technically, this can be translated as:
The silver automotive part in the center is undergoing a milling process, with a two-piece fixture, consisting of dark gray components on the left and right, securely clamping the workpiece in position during machining.
To achieve accurate and consistent material removal, machining fixtures and jigs are essential. These holding or guiding tools provide stability during machining and ensure the interchangeability of produced parts.
Fixtures and jigs reduce the impact of human error and standardize the manufacturing process, making it controllable, measurable, and repeatable.
Machining jigs and fixtures ensure that workpieces and cutting tools are correctly secured, angled, and guided. These manufacturing aids may have different names depending on the type of cutting process, as well as the method of clamping or applying force to the workpiece. However, their primary function is to facilitate efficient machining by controlling the workpiece or the cutting tool.
Fixtures and jigs can be mass-produced or custom-made for specific tasks. They can also be created using both traditional and digital manufacturing methods and from a wide variety of materials.
Advances in the design and development of fixtures and jigs, though seemingly just supporting components of production, can significantly impact the overall success, accuracy, and consistency of the machining process.
The Importance of Precision in Machining
Machining is used to produce high-precision parts for industrial applications, and these parts are often made from materials such as metal, which are difficult to shape with high precision or costly if alternative manufacturing methods like casting or molding are used.
Furthermore, machining is a process that produces parts one by one, and material is lost in the form of chips removed during production. These characteristics make machining less suitable for mass production than other manufacturing processes.
Therefore, manufacturers choose machining due to the critical need for precision and accuracy in the workpiece.
This precision is partly supported by fixtures and jigs used in the production process, such as milling jigs, CNC workholding devices, or drilling fixtures.
These fixtures are crucial for the overall precision of the manufacturing process. The fixtures themselves must be highly accurate, maintain their shape without creep or deformation from pressure and use, and in many cases, must be specifically designed for each type of workpiece and machine.
Types of Machining Jigs and Fixtures
Customized Collet Pads are necessary to firmly hold metal parts within the spindle for each different workpiece in the production process.
More technically, this can be translated as:
Custom-designed collet pads for each workpiece are essential for securely holding metal components within the spindle to ensure precise production throughout the entire manufacturing process.
A well-known saying in the manufacturing industry goes:
"To make one thing, you must make four things first."
This concept accurately reflects the reality of manufacturing and holds true for machining fixtures and jigs.
In other words, before a real product can be manufactured, it is often necessary to design and produce various supporting devices, such as fixtures, jigs, clamps, or specialized tools, to ensure that the manufacturing process can proceed accurately, efficiently, and consistently.
Classification by Material or Manufacturing Process
Machining fixtures are typically made from metal. Traditionally, they are produced by CNC machining or milling from steel or aluminum, offering very high precision and strength.
Some types of fixtures may be produced by molding, but this process requires the prior creation of molds, which themselves must be machined. Moreover, most fixtures are produced in small quantities, making mold production economically unfeasible.
Producing fixtures using these traditional methods can take weeks before the actual part manufacturing process can begin.
Historically, on-demand fabrication of fixtures could be done with wood, but wooden fixtures often had disadvantages such as being large, bulky, and easily damaged, which reduced the precision of the resulting parts.
Currently, 3D printing technology has become a new and increasingly common option for manufacturing machining fixtures.
The availability of strong, durable, and high-temperature resistant materials, 3D printers at various price points, and high-precision 3D printing technologies make it easier for machine shops and workshops to produce custom-designed fixtures for each task, while ensuring high reliability and improving the accuracy of the cutting process.
In many cases, fixtures produced from polymers using 3D printing technology can replace metal fixtures. It also opens up possibilities for designing more complex fixtures, using less material, and achieving higher precision compared to traditional manufacturing methods.
Classification by Use or Function
Machining fixtures can be classified by various factors, such as the type of machining process they are used for, the power source used, or their function and method of clamping the workpiece.
The following types of fixtures are classified by the machining process they are applied to:
Milling Fixtures or Milling Jigs
Common fixtures used in milling include:
- Rotary Table Fixtures
- Vise Fixtures
- Fixture Plates
- T-Slot Fixtures
- Indexing Fixtures
These devices are used to hold the workpiece or material blank onto the milling machine table, ensuring the workpiece is securely held while the milling head moves around it, removing material from the surface.
Turning Fixtures
In turning, fixtures hold the workpiece securely onto a high-speed rotating assembly, while a stationary cutting tool removes material upon contact with the rotating workpiece.
Fixtures used in turning include:
- Faceplate Fixtures
- Collet Fixtures
- Chuck Fixtures
- Mandrel Fixtures
Grinding Fixtures
Devices used to hold workpieces during surface grinding include:
- Centerless Fixtures
- Magnetic Chuck Fixtures
- Sine Bar Fixtures
Drilling Fixtures
Similar to common drills, drilling fixtures are found in both industrial settings and household tasks, such as cabinet or furniture making.
Depending on the application, these devices can be:
- Fixtures that hold the workpiece stationary
- Jigs that guide the drilling angle and path correctly
Boring Fixtures
In the boring process, the following are used:
- Boring Bars
- Boring Head Fixtures
to help guide the direction, angle, and appropriate force for the boring tool's cutting action.
Classification by Power Source
Fixtures can also be classified by the power source they use, such as:
- Hydraulic systems
- Pneumatic systems
- Electrical systems
- Manual control systems
- Vacuum systems
- Magnetic systems
Classification by Workholding Method
Fixtures can also be classified by how they grip or control the workpiece.
- Vise Fixtures use external clamping force to hold the workpiece in place.
- Jig Fixtures are used to guide the cutting tool's movement along a predetermined pattern.
- Angle Fixtures are used in CNC milling to maintain the precise cutting angle or direction of force from the tool as required.
Each type of fixture is designed for specific manufacturing processes, with the common goal of enhancing the accuracy, consistency, and efficiency of the machining process.
Fixtures and Jigs for Other Metalworking Processes
This Straight Arm Jig consists of two small 3D printed parts mounted on a steel plate.
The shape of the parts is complex and features organic, freeform curves, which are difficult to produce with traditional machining processes. Additionally, the team needed to use this tool within just one day.
After using the jig for approximately 2,000 welds, it was still fully functional, despite occasional accidental drops of spatter or weld beads on its surface, which did not affect its usability in any way.
Although welding is not a subtractive manufacturing process like CNC turning, milling, or machining, it is another task where fixtures and jigs, especially those produced with 3D printing technology, have proven highly beneficial in reducing waste, lowering costs, and increasing process efficiency.
Welding jigs can be used for a variety of applications, such as:
- Fit Tests
- Securing workpieces in position
- Guiding robotic welding operations
- Supporting various steps within the welding process
The benefits are similar to those for CNC fixtures, milling jigs, and other manufacturing aids: these devices help make metalworking processes more accurate, consistently repeatable, and yield more correct results.
By having appropriately designed manufacturing aids, factories can enhance work quality, reduce errors, and maintain production standards efficiently.
3D Printing as an Option for Custom Fixture Design
As with many other industries and applications, 3D printing technology has opened new opportunities for producing machining jigs and fixtures more efficiently and at a more accessible cost.
3D printing allows for faster iteration and development, making the product development process more comprehensive, supporting more efficient designs, and offering a low-cost manufacturing method for one-off or low-volume jigs and fixtures.
Manufacturing aids, when well-designed and produced, not only enhance their own operational efficiency but also positively impact subsequent stages of the production process (Downstream Effects).
The results can range from improving overall manufacturing process efficiency to elevating the quality and performance of end-use products.
Advantages of Using 3D Printing Technology for Manufacturing Jigs and Fixtures in Machining
In Pankl Racing Systems' production line, each operation on the automatic lathe requires a specific 3D-printed CNC lathe jig designed for that particular step.
These jigs are mounted onto a conveyor belt using standard shuttles, allowing for precise and efficient movement of workpieces through each production station.
Perhaps the most commonly understood advantage of in-house 3D printing is accelerated development. The ability to iterate on prototypes and designs more frequently leads to a more thorough and comprehensive design and testing process. This ensures that products, whether end-use parts or manufacturing aids, are more rigorously tested and developed.
This speed advantage is particularly significant for manufacturing aids, as delays in their production can bottleneck prototyping or other production steps.
Considering the downstream effects on the production process, as well as the impact on the quality of finished products, CNC fixtures such as CNC workholding clamps should perhaps receive more design consideration than they currently do.
3D printing prototypes of jigs and fixtures for milling or machining allows manufacturers to test the fit and function of these tools—a step often overlooked in the past, as fixtures and jigs were typically viewed as mere accessories in the production process.
Such a process can lead to better designs and more efficient material use. For example, operators might find that parts should be improved ergonomically for easier installation, removal, or replacement.
It also opens up opportunities for customization. CNC machines, such as CNC turning tables, are often mass-produced as standard units, but their operational programs and the parts they produce are unique to each manufacturer.
CNC jigs and fixtures can serve as a bridge between these standard tools and specific requirements, simply by improving the CNC fixture design process.
The design flexibility of 3D printing technology, especially those that do not require supports, such as Selective Laser Sintering (SLS), also allows for the creation of more complex, customized, and application-specific fixtures and jigs.
The digital nature of 3D printing also allows for more efficient file management. If a large manufacturer has 3D printers installed in multiple facilities, they can improve production processes across all locations simultaneously by simply sharing CNC fixture design files that enhance the efficiency of common machinery.
3D printing facilitates more efficient and impactful knowledge transfer, enabling large companies to quickly and easily develop and improve performance at every level of their manufacturing network.
Furthermore, the variety of materials supported by each type of 3D printing technology makes 3D printed jigs and fixtures more flexible and applicable in a wider range of situations.
For instance, 3D-printed welding fixtures need to withstand high temperatures. Certain stereolithography (SLA) resin materials, such as High Temp Resin or Rigid 10K Resin, can be a cost-effective, on-demand, and faster alternative to producing metal welding fixtures.
Meanwhile, 3D printing nylons, such as Nylon 12 Powder or Nylon 11 Powder, are ideal for producing machining fixtures like chucks, which require both durability and strength to securely hold workpieces during high-speed turning processes.
3D Printing vs. CNC Machining for CNC Fixture Production
A machine gripper picks the workpiece from the first jig (the dark green part in the middle) and places it on the second jig after the machining process is complete.
Or, to phrase it more fluidly in an industrial context:
After the machining process is completed, the automatic gripper of the machine transfers the workpiece from the first jig, the dark green component in the center, to the second jig, preparing it for the next stage of production.
When deciding whether to use 3D Printing or CNC Machining for fixture production, key factors to consider include:
- Material Properties
- Part Complexity
- Lead Time
In terms of material properties, fixtures and jigs for machining often do not require highly technical materials beyond adequate strength and durability.
Common industrial plastics such as Nylon typically offer sufficient properties for most applications.
However, in some cases, specific properties may be necessary, such as:
- Conductivity
- High Heat Resistance
In such situations, stereolithography (SLA) 3D printing technology can be an excellent choice, as it supports a wide variety of specialized materials designed to meet different operating environment demands.
Once the required pressure, clamping force, or friction level for a fixture or jig can be estimated, manufacturers can consult material data sheets from 3D printer manufacturers to select the most suitable material for the task.
For example, The Factory Amsterdam, a machine shop in New York, found that Nylon 12 Powder printed with the Fuse SLS Series machines performed effectively in the high-speed CNC turning processes used at their facility.
| Material | Ultimate Tensile Strength (MPa) | Tensile Modulus (GPa) | HDT @ 0.45 MPa (°C) | Notched Izod (J/m) |
|---|---|---|---|---|
| Nylon 12 Powder | 42 | 1.45 | 171 | 16 |
| Rigid 10K Resin | 88 | 11 | 238 | 20 |
| Tough 2000 Resin | 46 | 2.2 | 63 | 40 |
| High Temp Resin | 49 | 2.8 | 238 | 17 |
Another factor to consider is part complexity.
For some types of fixtures, such as collet pads, the parts themselves have relatively simple shapes, and CNC lathe manufacturers often offer standard steel parts.
For jobs requiring the production of thousands or hundreds of thousands of identical parts, metal fixtures produced by CNC machines remain a proven option for excellent long-term use.
However, when fixtures or jigs become more complex, such as testing fixtures for welding machines that need to accommodate switching between multiple programs, production using CNC processes becomes more expensive and complicated.
The most crucial factor in deciding whether to choose 3D Printing or CNC Machining for manufacturing fixtures and jigs is time.
The important question is:
How quickly do you need these parts?
In most manufacturing environments, the worst-case scenario is a production stoppage due to the lack of necessary fixtures or jigs.
If you rely on CNC production for these parts, especially when using metal for both prototyping and final part production, the work will add to the machining department's queue and could become a bottleneck impacting the entire business's production capacity.
Conversely, manufacturing fixtures with 3D printing technology can deliver parts within a few hours, without diverting resources or time from machinists needed for other primary projects, which is often difficult to avoid with CNC production.
Therefore, for fixtures and jigs that undergo frequent design changes, require urgent delivery, or are highly complex, 3D Printing often offers advantages in terms of speed, flexibility, and reducing production bottlenecks. Meanwhile, CNC Machining remains suitable for parts requiring long-term use, high stress resistance, and high-volume repetitive production.
Which 3D printing technology is best suited for fixture manufacturing?
There is no single "best" 3D printing technology for manufacturing machining fixtures in all cases. The choice of suitable technology depends on various factors, and many companies often use multiple types of 3D printers in conjunction.
The three most popular 3D printing technologies currently are:
- Fused Deposition Modeling (FDM)
- Stereolithography (SLA)
- Selective Laser Sintering (SLS), sometimes referred to as Powder Bed Fusion
When selecting a printer for manufacturing milling jigs, CNC fixtures, drilling fixtures, or other types of manufacturing aids, the following factors should be considered.
Or, if used as a sub-heading in the article:
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Customized collet pads are required to securely hold metal parts within the spindle for each type of workpiece in the manufacturing process. Or, to phrase it more fluidly in an industrial context: Due to the varying shapes and sizes of workpieces, custom-designed collet pads are essential for securely holding metal components within the spindle throughout the production process, ensuring precise and consistent machining. |
Selective Laser Sintering (SLS) 3D printing technology particularly excels in producing small parts such as collet pads, which are consumable parts. Although these parts need to be replaced after use, they must be durable enough to support the production of 3,000 to 4,000 units per cycle. Furthermore, collet pads must withstand the radial forces generated by the lathe's rotation, which can reach speeds of up to 3,000 revolutions per minute (rpm). |
SLS is suitable for applications requiring:
Strong, durable, and heavy-duty tools
Parts that endure high forces and repeated stress, such as machining fixtures or milling fixtures that need to withstand impact.
Versatile materials, chemical resistance, and environmental stability
Nylon 12 Powder is a popular material for general 3D printing. Nylon parts absorb very little moisture and are highly resistant to light, heat, and chemicals.
This property is crucial for tools in machining, as they often come into contact with cutting oils and various lubricants.
Formlabs recommends Nylon 12 Powder as the standard material for most applications. For more specialized requirements, it is advisable to consult the SLS material catalog to select the most suitable material.
Complex shapes and lightweight designs
SLS does not require support structures, offering high design freedom. It can create parts with intricate details, hollow internal structures, or shapes difficult to produce by other methods.
Furthermore, lattice structures can be designed to reduce material usage and part weight while maintaining strength, making it ideal for large jigs in sheet metal forming or replacement parts for machinery.
High throughput production
SLS is suitable for medium-volume production.
Because it doesn't require supports, operators can nest multiple parts within the print area, reducing post-processing time.
The build chamber of the Fuse 1+ 30W allows for dense packing of parts throughout the print volume, increasing the number of parts per build cycle, enhancing efficiency, and boosting overall productivity.
Additionally, Fuse Sift and Fuse Blast simplify powder management, powder recovery, as well as automatic cleaning and surface finishing of parts, making the post-processing workflow much more efficient.
Or, if used as a sub-heading in the article:
These 3D-printed lathe jigs, manufactured from Formlabs' previous generation Tough 2000 Resin, offer exceptional strength and high precision.
These jigs can be precisely mounted onto the standard shuttles used in the system and also provide a secure and stable grip on the workpiece.
These properties enable precise and consistent movement and positioning of workpieces in the production process, efficiently supporting operations on the production line.
SLA is suitable for applications requiring:
High precision, sharp details, and smooth surfaces
Ideal for applications demanding high accuracy, such as:
- Machining Alignment Tools
- Location Jigs
- Measurement Devices
- Ergonomic Fixtures
Furthermore, specialized details can be easily added, such as custom grips designed for user ergonomics to enhance usability.
Diverse material properties and easy material switching
SLA systems support a wide range of specialized resins, allowing for the production of tools that meet the specific requirements of each task, such as:
- Elastic Materials
- ESD-Safe Materials
- Flame-Retardant Materials
to support specialized applications in different environments.
One of the popular materials in metal processing is Rigid 10K Resin, particularly for the production of welding fixtures.
This material offers high stiffness and excellent temperature resistance, with:
- An HDT (Heat Deflection Temperature) of 218°C @ 0.45 MPa
- A Tensile Modulus of 10,000 MPa
making it suitable for applications requiring high rigidity and dimensional stability.
Rapid, low-volume production with an accessible system
The Formlabs SLA printer ecosystem has a lower initial cost, requires fewer accessories, and can be easily integrated into existing production processes.
Users can transition from design to functional parts in just a few hours with the Form 4 and Form 4L 3D printers.
This makes them ideal for rapidly producing fixtures, jigs, or manufacturing aids, as well as for applications involving frequent design changes or updates.
Or use as a sub-heading in an article
FDM is suitable for applications requiring:
Fast Prototypes
FDM 3D printers excel at rapid prototyping, especially for creating "looks-like" models to check external appearance and fit.
They are ideal for verifying dimensions, shapes, and preliminary assembly before opting for other manufacturing methods for final parts.
Affordable Parts
Desktop FDM printers are the most popular and well-known 3D printers on the market.
Not only are the machines themselves affordable, but the printing materials are also inexpensive and readily available from various manufacturers and suppliers.
Multi-Person Teams or New Users
FDM is the most widespread 3D printing technology, meaning many users are already familiar with its operation.
Therefore, when new members join a team, they can usually learn and start using this type of printer more easily than other 3D printing technologies.
Familiar Materials in Industry
FDM printers support materials widely known and used in industrial sectors, such as:
- ABS
- PETG
- PLA
- ASA
- Polycarbonate (PC)
- Nylon (some systems)
These materials have properties and behaviors that most manufacturers are already familiar with, simplifying material selection and performance evaluation of parts.
For these reasons, FDM is an excellent choice for rapid prototyping, low-cost parts, use within large teams, and applications requiring standard and easily understood industrial materials.
Custom Jig and Fixture Creation with 3D Printing Technology
3D printing excels particularly in producing custom parts or low-volume parts.
CAD design software allows machinists to create designs perfectly optimized for specific applications, whether it's CNC fixtures or workholding clamps precisely tailored to both the workpiece and the machine.
3D design also enables the creation of complex geometries, such as:
- Overhangs
- Lattice Structures
- Other special geometric shapes
These can be difficult to produce with traditional machining processes but offer advantages in reducing material usage and part weight.
3D printing can thus deliver both strength and operational efficiency simultaneously. In many situations, these design and performance advantages might be more significant than the increased strength from producing metal fixtures or jigs.
When creating properly designed machining fixtures, whether it's a:
- Milling Fixture
- Turning Fixture
- Grinding Fixture
- Drilling Fixture
There are basic steps to follow to fully utilize 3D printers and selected materials.
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Collet pads produced with SLS 3D printing technology require exceptionally high dimensional accuracy and precision to ensure a snug fit and perfect installation onto the spindle. Even minor deviations in part dimensions can cause problems for the integrity of the turning process, such as unstable clamping, unbalanced rotation, or reduced machining precision, potentially affecting part quality and overall production efficiency. |
These tools are constantly exposed to coolant within the lathe. The coolant used is semi-synthetic oil, which can corrode or react with many plastics. Many FDM 3D printing materials can be damaged or dissolve upon contact with this type of oil. In contrast, Nylon 12 Powder has high chemical resistance, allowing it to withstand contact with such coolants without wear or degradation from use. This property makes Nylon 12 Powder ideal for producing collet pads, fixtures, and workholding devices that must operate inside machinery and be continuously exposed to coolant. |
Digitize Existing Tooling with Reverse Engineering
Transform existing tools into a digital inventory or use them to analyze tooling requirements and design new tool files.
When designing jigs or fixtures for 3D printing, there are several considerations that differ from traditional machined metal tools, opening up opportunities to create unique features only possible with additive manufacturing technology.
Leverage Complex Geometries
Use 3D printing to create intricate internal details, such as:
- Internal channels
- Undercuts
- Hollow internal structures
These shapes are difficult and costly to produce with metal machining.
- SLA is suitable for applications requiring high detail and smooth surfaces.
- SLS is suitable for complex geometries requiring strength and good mechanical load-bearing capacity.
Optimize for Lightweight Structures
Utilize SLS to create lightweight jigs with structures like:
- Lattice Structure
- Honeycomb Structure
This helps reduce the weight of the part without compromising strength.
This is difficult to achieve with solid metal parts produced by traditional machining.
Design with Precise Wall Thickness
SLA can precisely create highly detailed parts with thin walls. Typically, wall thickness can be designed to be around 2–3 millimeters.
While not always thinner than metal, SLA allows for complex shapes and smooth surfaces without additional machining, improving efficiency and reducing production costs.
Integrate Multiple Functionalities
3D printing allows for combining multiple elements into a single part, such as:
- Clamps
- Locators
- Guides
This simplifies the design and reduces the need to assemble multiple components.
Incorporate Smooth Fillets for Strength
SLA can add fillets with a radius of approximately 1–2 millimeters in stress-bearing areas.
This helps reduce:
- Crack formation
- Stress concentration
While fillets can also be made in machined metal parts, 3D printing allows for creating shapes that are more resistant to stress with fewer production steps.
Enhance Ergonomics
Ergonomic details can be directly integrated into the part design, such as:
- Specialized grips
- Curved edges for hand comfort
- Tactile surfaces
These features improve usability and can be achieved more easily and economically than with traditional metal manufacturing.
Design for Modularity and Customization
SLS is ideal for creating modular jigs and fixtures.
Advantages include:
- Easy modification
- Ability to update only specific sections
- Replacement of individual parts
without needing to produce an entirely new tool set, unlike metal tooling.
This saves both time and cost.
Reduce Assembly with Single-Part Designs
3D printing helps integrate complex assemblies into a single part.
Advantages include:
- Reduced assembly time
- Reduced risk of incorrect assembly
- Reduced number of parts to manage
Both SLA and SLS can help simplify the production process compared to multi-part metal fixtures.
Consider Additional Finishing Steps
Post-processing steps vary depending on the technology used.
For machining jigs and fixtures, an aesthetically pleasing surface finish like painting, plating, or coating is generally not required.
For SLA
- Wash the part
- Dry
- Remove supports
For SLS
- Remove excess powder
- Media blast
For FDM
- Remove supports
- Sand
These steps are typically sufficient for use as fixtures and jigs in most manufacturing processes.
SLA and SLS 3D Printing: Powerful and Efficient Options for Machining Fixtures and Jigs
Formlabs printers, including the Fuse 1+ 30W, Form 4L, and Form 4, are ideal tools for producing machining fixtures and jigs.
Machining fixtures are critical components for the success of machining operations, bridging the gap between mass-produced standard machines—be it mills, lathes, welders, cutters, drills, boring machines, and other equipment—and the specific products manufacturers aim to create.
3D printing has emerged as a new alternative to traditional fixture and jig manufacturing processes. With a wide range of materials and technologies available, the speed and efficiency of printers, and the ability to customize for specific applications, many manufacturers are adopting 3D printing technology within their organizations.
The benefits not only reduce the workload for machinists but also enhance overall manufacturing process efficiency and can positively impact business profitability.
If you intend to start producing fixtures and jigs for turning, milling, or any type of machining process, you should begin by assessing your own needs, such as:
- The type of material required
- Necessary mechanical properties
- Areas where efficiency can be improved or production processes optimized
- The required build volume
Once these needs are understood, you can then select the appropriate 3D printing technology, whether SLA or SLS, to best match the application and manufacturing goals.
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References
https://formlabs.com/global/blog/machining-fixtures-milling-cnc-workholding-jigs-3d-printing/
