Reduce downtime and costs by moving the production of tools from traditional milling to additive manufacturing.
Speed and precision drive competition in the industry today. Many still associate 3D technology primarily with prototypes, but at 3D actions, we see that companies are increasingly using the technology to optimize their production lines. We focus here on “tooling” – meaning production aids such as jigs, fixtures, molds, and transport brackets. If you move the production of these tools from traditional CNC milling to additive manufacturing, you save both time and money.
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What are jigs, fixtures, and dunnage in an industrial context?
To understand the value, we must define the terms precisely. A jig is a tool that guides another tool, for example, a drill template that ensures the operator drills in the exact spot every time. A fixture is a device that holds a part in a specific position during machining, assembly, or welding.
The term also covers “Rapid Tooling”. Here, we manufacture molds for injection molding or thermoforming directly on a 3D printer. This allows you to validate material selection and design with functional prototypes in the correct end material before you invest in expensive steel molds.
Finally, it includes “dunnage” or contour boards. These are custom-made transport fixtures that carry irregular parts safely through the supply chain. The aviation industry is currently replacing complex wooden structures with 3D printed contour boards. This ensures that they transport sensitive aircraft parts like flaps and ailerons from the “flight line” and back to the workshop without damage. The industry traditionally manufactures these parts in aluminum, steel, or wood, which is an expensive and slow process. A professional 3D printer delivers a solution where you go from a digital drawing to a physical tool in just a few days.
How do you calculate ROI on 3D printed production equipment?
You gain the greatest benefit from the “Total Cost of Ownership” (TCO) and by reducing “opportunity cost.” We do not just calculate value based on the price of the 3D print itself, but from the value of the time saved.
The industrial company Multiplus shows the potential when switching to 3D printed injection molds. For small series production of around 100 parts, they reduced lead times from 4 weeks to just 3 days by using high-performance resins instead of metal molds.
For companies with turning centers (Swiss machines), downtime is critical. Iscar demonstrates how modular 3D printed tool heads allow for rapid changes with a repeatability of +/- 0.02 mm. The operator changes the head without having to recalibrate. The calculation is simple: if a production stop costs 10,000 INR per day in lost revenue, the price of the 3D print itself means nothing compared to the 20-30 days of waiting time you save. This supply security drives your ROI.
Why does 3D technology surpass traditional milling for these specific parts?
The difference between traditional CNC milling and professional 3D print becomes clear when looking at parameters such as lead time and design freedom. Where traditional machining in aluminum or steel often involves high startup costs for CAM programming and material waste, 3D print has low startup costs with no minimum quantity requirements. Delivery times typically drop from 3-6 weeks to 2-4 days when using local production.
Weight also plays a role. Metal fixtures are heavy, which strains both operators and robots. A 3D printed solution in polymer or composite is lightweight, improving ergonomics and allowing for faster cycle times for robots.
Beyond speed, a 3D printer offers design freedom that traditional methods rarely match. Cosmetics manufacturer Lush goes from idea to finished mold in under 24 hours. They test over 1,000 designs annually via 3D printed vacuum molds, giving them a significant advantage in product development. The same logic applies to internal channels. While the metal industry uses 3D print to create optimized cooling channels in cutting tools to avoid cavitation, we use the technology to print grippers with internal vacuum channels. This geometry is impossible to mill in one piece but essential for efficient robotic solutions.
Which materials are best suited for harsh production environments?
We select materials based on load and environment. We draw on a wide range of materials, from strong filaments to detailed resins.
PLA for simple tasks
Use this for simple templates and spacers without requirements for heat or chemicals. This is the most economical solution.
PETG and TPU for flexibility and chemistry
PETG resists chemicals and impacts. TPU (a flexible rubber-like material) protects parts from scratches during transport.
Nylon and carbon fiber for strength
Choose Nylon (PA12) or carbon fiber-reinforced materials when strength and stiffness are paramount. These materials often replace aluminum for clamping tools. Students from TU Berlin, for example, use molds printed in “Tough” resin to hand-laminate carbon fiber parts for racing cars. The mold maintains its shape during layup but is flexible enough to allow them to release the finished part after curing.
High-performance resins for molds
For injection molds and thermoforming, we use materials like “Rigid 10K.” It is glass-reinforced and withstands high temperatures and pressures without deforming. This ensures a smooth surface that is transferred directly to the end product.
How do functional mock-ups reduce risk in production?
A “Functional Mock-up” minimizes the risk in your production. Before you receive an expensive cast component from a subcontractor—which may have a 12-month lead time—you should test your own assembly process.
General Electric (GE) experienced this when waiting for a large cast hub for a wind turbine. They printed a 1:1 model of the hub and validated their entire production line, tested lifting equipment, and ensured space for cabling long before the actual metal part arrived.
This principle also applies to CNC machining. Run a “dry test” of a machining program on a cheap 3D printed plastic copy (a “machining mock-up”). If you discover a programming error, it is better to destroy a piece of plastic than to crash the tool into an expensive steel casting. At our facility, we see this as part of our 3D actions philosophy: we ensure quality before quantity.
3 concrete applications in your production
We have identified three areas where 3D printed solutions create the greatest value for industrial customers.
1. Assembly fixtures and grippers Do you have parts with complex geometries that are difficult to clamp? A 3D printer manufactures “soft jaws” or negative molds that fit the part’s surface precisely. This keeps the part stable without scratching. We often see this used for robotic grippers, where carbon fiber-reinforced material reduces weight, protects the robot, and allows for faster movements.
2. Functional mock-ups for process validation Validation also applies to consumer products. The company OXO uses 3D printed molds to compression-mold silicone gaskets. This allows them to test the function of rubber parts in the correct material before ordering the final production tool.
3. Custom transport protection Transporting irregular parts creates challenges. Hydraulic cylinders are round and heavy, making them unstable on a standard pallet. We print specific holders that match the cylinder’s diameter exactly. This secures your components during transport without requiring investment in expensive injection molding tools for the packaging. 3D print rarely competes with single-use packaging in price, but it is often the most economical solution for returnable packaging and internal logistics systems that you reuse.
How does the process with a digital warehouse of tools work?
You no longer need to keep physical spare parts for your production machines on the shelf. With a digital warehouse at our facility, you order new jigs or spare parts on-demand. You free up storage space and tie up less capital.
The workflow is simple: you design the tool in CAD and save the file digitally with us. When the tool wears out or is lost, you take the action of ordering a new print, and we deliver a new part within a few days.
How do you get started with ordering?
Are you facing a challenge in production where standard tools fail? First, ensure you have the correct files. We typically work with STL or STEP files for 3D print.
Send us a file of your part or a sketch of the problem. We will advise you on whether an FDM solution in strong carbon fiber or an SLA solution in smooth resin best solves the task for your production.
FAQ: 3D print for production
Here you will find answers to the most common questions regarding the use of additive manufacturing to optimize production lines, tools, and logistics.
How do 3D printed jigs and fixtures streamline production?
Efficiency is increased by moving manufacturing from CNC to 3D print, which reduces lead times from weeks to days. This minimizes machine downtime, improves ergonomics with lightweight tools, and enables rapid design iterations without high startup costs, ensuring a more agile and profitable production line.
Which materials can be used for 3D printed jigs?
We select materials based on the specific load, chemistry, and temperature in your production environment. For simple tasks, economical PLA is used, while we utilize impact-resistant PETG, flexible TPU, or carbon fiber-reinforced nylon for demanding clamping tools intended to replace aluminum and withstand harsh industrial use.
Can 3D print replace aluminum and steel for tools?
Yes, modern composite materials like carbon fiber-reinforced nylon or glass-filled resin offer high strength and stiffness. While they do not have the same hardness as steel, they are ideal for fixtures, grippers, and jigs as they significantly reduce weight and protect parts from scratches, while being fast to manufacture.
How fast is the delivery time for 3D printed parts?
The lead time for 3D printed parts from local production is typically 2-4 business days. This is significantly faster than traditional milling, which often takes 3-6 weeks. This speed makes it possible to implement a digital warehouse where you order spare parts on-demand as the need arises.
What is the advantage of functional mock-ups in production?
Functional mock-ups minimize the risk of expensive errors by validating the design before final production. By printing an affordable 1:1 model, you can test assembly processes, CNC programming, and fitment early in the process, preventing damage to expensive equipment and ensuring everything fits together when the final parts arrive.
Which file types should be used for ordering 3D print?
To order 3D print, you typically need 3D files in STL or STEP formats. These formats contain the necessary geometric information our software needs to generate the print. If you only have a 2D drawing or a sketch, we can often help with advice on conversion.
Create measurable results with additive production tools
Implementing 3D printed jigs, fixtures, and tooling is a validated strategy for production optimization. You reduce lead times on molds from weeks to days, minimize risk through functional mock-ups, and improve ergonomics with lightweight fixtures. The technology shifts your costs from passive inventory holding to active value creation.
Contact our team today to hear how we can elevate your production.
