Posted on 24/06/2025

Advantages of 3D printing in the production of tools and jigs

In today's manufacturing industry, where precision, agility, and efficiency are essential, 3D printing is positioned as a transformative technology. Its application in the production of specific tools such as *jigs, fixtures, positioning tools, and clamping tools* is making a notable difference in terms of costs, production times, and design possibilities.

What are jigs, fixtures, and positioning and clamping tools?

They are fundamental elements used to guide, align, or hold components in place during manufacturing and assembly processes. *Jigs* are typically used to guide a tool (e.g., a drill bit), while *fixtures* secure the workpiece in position. Both tools are custom-designed for specific tasks, ensuring precision, repeatability, and reduction of human error.

However, traditional manufacturing methods—such as CNC machining or injection molding—involve prolonged lead times, high costs, and geometric limitations. The need for skilled personnel and production complexity lead many companies to accumulate spare stock of these types of parts to minimize disruptions, which in turn increases storage and management costs.

A 3D printed holder for a digital caliper. Source: Hackernoon.com.

Why is 3D printing revolutionizing the manufacturing of jigs, fixtures, and tools for industrial use?

Additive manufacturing enables the in-house production of these tools with unprecedented speed and flexibility. From a CAD file, a functional tool can be obtained in a matter of hours, representing a lead time reduction of between 40% and 80%, and cost reductions of up to 95% compared to conventional methods.

Furthermore, 3D printing removes design barriers: it allows for the creation of complex geometries that would be impossible or prohibitively expensive with traditional machining. This translates into more ergonomic tools, adapted to the operator or product, and optimized for the real workflow.

What 3D printing technologies are used for tools and jigs?

FDM (Fused Deposition Modeling)
Ideal for functional tools, this technology uses plastic filaments such as PLA, ABS, polycarbonate, or nylon. It is a robust, economical technology suitable for parts subjected to handling or moderate stress. The use of specific materials—such as carbon fiber reinforced filaments or chemical-resistant ones—further expands its applicability.

SLA (Stereolithography)
Provides high resolution and smooth, polished finishes. It is optimal for small, detailed tools that require tight tolerances (up to ±0.05 mm). Advances in technical resins have improved mechanical and thermal resistance, allowing their use in demanding applications such as electronic components or medical devices.

SLA resin printed drill guide jig. Source: Formlabs.com.

SLS (Selective Laser Sintering)
With materials like Nylon 12 or fiber-reinforced variants, this technology allows for printing complex and highly resistant parts without support structures. It is especially suitable for designs with internal geometries, integrated movable mechanisms, or lattice and reticular structures. Its strength makes them a real alternative to aluminum machining in industrial environments.

Direct pellet extrusion and emerging technologies
Industrial systems that print directly with pellets offer advantages in cost and volume. They allow for printing large parts and utilizing recycled materials, which is ideal for large tools.

What economic benefits does it provide?

3D printing eliminates tooling costs, minimizes material waste, and automates much of the process. Companies can manufacture only what is needed, without unnecessary stock or minimum orders. A single operator can supervise several printers working simultaneously and without interruptions, even overnight or on weekends. This approach not only frees up skilled human resources for higher-value tasks but also shortens design and development cycles for new products.

Industries report savings of 70% to 95% in costs, and reductions of 90% in delivery times. Brands like Opel have adopted this technology to manufacture assembly tools significantly cheaper and faster than traditional ones.

What new design possibilities does additive manufacturing allow?

Geometric freedom is one of the main advantages. Unlike machining, where physical limitations force simplification of designs, 3D printing allows for optimized tools to be created from the outset: organic shapes, internal structures, vacuum channels, integrated guides, movable mechanisms printed in a single piece… even tools with articulated parts or ergonomic handles.

This capability allows not only for functional improvement but also for weight reduction, material savings, and part consolidation. The result: more precise, resistant tools adapted to each task, without penalties in costs or times.

How does additive manufacturing facilitate functional customization?

One of the most significant advantages of 3D printing in production tools is its ability to precisely adapt to each component or process. Instead of resorting to generic tools, it is now possible to design jigs and fixtures specifically for a particular part. For example, a perfectly adapted support can be created for the geometry of a unique PCB or a customized component, starting directly from the product's 3D model. This precise customization not only improves fit and functionality but also increases assembly efficiency and reduces errors.

Furthermore, this technology is particularly useful when working with unique, discontinued, or hard-to-access parts. What was once unfeasible due to high production costs is now feasible through rapid and economical printing. In sectors that maintain older equipment, this capability extends the operational life cycle and reduces dependence on external suppliers.

The iteration process is also favored: if a tool doesn't fit perfectly, the CAD design can be adjusted and reprinted the next day, without the need for expensive reworks. This dynamic allows each tool to be fine-tuned until an ideal fit is achieved. It is even possible to design small variants of the same jig to adapt to different models or operator preferences, such as left-handed versions or those with specific handles. In this way, true *mass customization of tools* is achieved, without additional costs.

Woodworking jig printed in 3D. Source: Matterhackers.com.

Additionally, these tools can be easily integrated into existing workflows. Fixtures with specific angles can be printed for use by robotic arms, or with integrated connections for machines or conveyor belts. And if the product changes, simply update the digital model and generate a new version. 3D printing thus transforms tooling into a dynamic resource, always synchronized with the needs of the production process.

Why is rapid design iteration key in tool creation?

The ability to print tool prototypes in a matter of hours drives a new approach to continuous improvement. An engineer can design a tool, print it, test it, and adjust the design the next day. This speed of iteration allows for quickly validating different ideas, fine-tuning adjustments, and optimizing geometries without economic penalty.

Any error or improvement identified during testing becomes an opportunity: instead of accepting a suboptimal tool, the model is corrected and a new version is printed, with minimum effort and cost. This agility fosters innovation, as teams can test creative solutions with the assurance of being able to modify them immediately if necessary.

Concurrent iteration between product and tool is another key advantage. As the product design evolves, fixtures can also adapt. The result is a simultaneous development that reduces the total time to implementation.

In many cases, the prototype of a printed tool directly becomes the final version. And if not, the feedback obtained guides the next version. Even after use, operators can propose improvements, which are implemented quickly. This establishes a continuous improvement cycle that was not viable with traditional methods.

What ergonomic and functional benefits does a printed tool provide?

Weight is a critical factor in hand tools or those mounted on mobile equipment. Jigs printed from technical polymers are considerably lighter than their metal equivalents. In addition, techniques such as internal hollowing or gyroid/lattice patterns allow for maintaining structural strength while minimizing overall weight. In industrial applications, weight reductions of up to 70% have been reported, facilitating manual use and reducing operator fatigue.

This lightening also improves the performance of automated systems: a lighter tool allows for faster and more precise movements in robotic arms, while reducing wear on motors and mechanisms.

3D printing also enables advanced ergonomics. Ergonomic grips, triggers, or surfaces adapted to the operator's anatomy can be integrated from the design stage. This attention to comfort not only improves user experience but also reduces the risk of injury and increases productivity.

It is even possible to design elements with a certain flexibility or cushioning, using specific materials or appropriate infill patterns. Thus, a surface can gently adapt to the user's body or a delicate part, without compromising functionality.

What does digital inventory and on-demand production imply?

Thanks to 3D printing, manufacturers can adopt a *just-in-time* approach to tooling as well. Instead of maintaining physical stock of tools, they store digital files that are printed only when needed. This drastically reduces the necessary space and costs associated with storage, maintenance, and inventory management.

There are no more minimum orders: a single tool can be manufactured if required, with no economic penalty. And if a tool is damaged during production, it can be reprinted immediately, minimizing line stoppages.

This approach also allows for global process standardization. A CAD file can be sent to any plant and reproduced locally with complete fidelity. This replicability facilitates coordination in multinational environments and accelerates the implementation of improvements.

Furthermore, digital inventory reduces obsolescence. If a design changes, the file is updated. There is no need to discard physical tools that are no longer useful. In some cases, plastic materials can even be recycled, closing the loop in a more sustainable way.

Example of a 3D printed jig for industrial assembly. Source: Javelin-tech.com.

How does material choice influence tooling performance?

3D printing allows for selecting the optimal material according to the intended use of the tool. There are filaments, resins, and powders with specific properties: mechanical, thermal, chemical resistance, electrical conductivity, biocompatibility, among others.

For example, FDM filaments range from PLA or ABS to carbon fiber reinforced composites, ideal for rigid tools. There are also ESD-resistant versions for electronics, or high-performance ones like PEEK for extreme environments.

In SLA, rigid resins or high-temperature resistant resins allow for manufacturing tools with high precision and advanced characteristics.

SLS, for its part, offers powders like Nylon 12, with variants adapted to different demands. It is possible to obtain robust, flexible, or other technical properties that rival the performance of many machined industrial plastics.

There are also multi-material or hybrid solutions, where metal components are inserted during printing, or rigid and soft zones are combined in the same piece. These possibilities open the door to tools with advanced functionality in a single process.

Where is all this applied? Sectoral examples

  • In the automotive industry, brands like Opel or Volvo Trucks have produced hundreds of printed tools for their assembly lines, with cost reductions of 90% and production times of only a few hours.

  • In electronics, they are used to position PCB boards during soldering, or to manufacture specific jigs for each component variant.

  • In aeronautics and defense, they are valued for their lightness, customization, and speed for maintenance tasks or low-volume manufacturing.

  • In medicine, customized surgical guides and assembly tools for delicate devices are printed.

  • In consumer goods, they allow lines to be adapted to short-run or seasonal products, without resorting to expensive metal tooling.

  • In construction, they are used to create complex plastic formwork or alignment tools for civil engineering.

  • In energy, they allow for on-site manufacturing of specific tools for maintenance, especially in remote locations.

  • In education and for makers, they leverage the same logic: low cost, agility, customization, and continuous improvement, accessible from any workshop.

All these cases have a common factor: 3D printing transforms the way work tools are conceived, manufactured, and used, from large factories to small creative spaces.

Conclusion

3D printing has completely redefined the production of tools and jigs in industrial environments, offering an agile, cost-effective, and highly customizable alternative to traditional methods. Thanks to its ability to drastically reduce costs, accelerate lead times, and eliminate design restrictions, this technology has consolidated itself as a strategic resource in improving production processes.

Source: Matterhackers.com.

Furthermore, its versatility in materials, ease of iteration, and the possibility of on-demand manufacturing allow companies of all sizes to respond quickly to market changes and the specific needs of their operations. In a context where efficiency, flexibility, and innovation are key factors, the adoption of additive manufacturing for the creation of jigs and fixtures represents not only a competitive advantage but a natural evolution towards a smarter and more adaptable production model.

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