According to a 2022 report by Make UK, 59 per cent of manufacturers indicated they plan to increase their expenditure on automation in comparison to the previous twelve months. The integration of advanced technologies, including robots, sensors and — of course — automation, requires production tools that can seamlessly integrate with these systems. Quickly designing and producing custom tools is vital for meeting short lead times and supporting rapid product development. Here Dave Bennett, bureau manager at 3D Print Bureau, explains how outsourcing the 3D printing of these tools can help.
We work with companies and manufacturers of all different sizes from across various industries, from general manufacturing to aerospace and automotive. Each of these sectors uses jigs and fixtures when producing components and requires tools that offer precision and accuracy. Equally, any jigs, fixtures and tools must be durable and reliable to withstand the rigours of manufacturing environments and minimise downtime.
More of our customers now value customisation and rapid prototyping. Being able to provide precise, efficient, flexible and durable tools cost-effectively is essential, which will help them stay competitive. 3D printing, or additive manufacturing (AM), can provide this flexibility and achieve quick turnarounds, and by working with a bureau, manufacturers can see these benefits without investing in a machine straight away.
Changing tools
Naturally, as any product evolves the manufacturing process must be tweaked to accommodate the redesign, which means having to retool and create new jigs and fixtures. When these tools are machined — as they traditionally are — this can be very costly and time-consuming, putting further pressure on manufacturers.
It’s not just design changes either. A tool currently in use could have been damaged or deformed on the factory floor, meaning it no longer functions as intended and could result in inconsistent production outputs. In reality, jigs and fixtures are used so regularly that they should be replaced on a regular cycle of around two years to prevent wear and tear and maintain safety standards.
AM offers an economical, flexible way of producing replacement jigs and fixtures, assembly and inspection aids, machining soft jaws and other tools. The advantage of using 3D printing is that these tools can be printed in hours rather than days or weeks, with improved ergonomics and design freedom.
Innovative, quality materials
Traditionally, jigs and fixtures are machined using metal, which, again, can be expensive when replacements are needed. As 3D printing technology has evolved, so have materials and there are now several options that are equivalent to metal. For example, Nylon 12 Carbon Fibre offers the highest flexural strength and stiffness-to-weight ratio of any fused deposition modelling (FDM) material. The combination of high strength, stiffness and light weight makes it an optimal replacement for heavier metal components. It is also protected against electrostatic discharge (ESD) — critical when working with electronic components and assemblies.
At our bureau, we provide customers with access to a wide range of AM technologies and materials. This ensures we create parts using appropriate filament and resins, with suitable properties for the application. Other options include flame, smoke & toxicity (FST) certified solutions like the ULTEM™ 1010 resin and biocompatible materials like PC-ISO, which is USP Class VI approved and ISO 10993-1 rated, making it suitable for food and drug packaging and medical device production. Importantly, all materials are validated and verifiable, providing full traceability.
Dedicated, expert support
By working with a bureau, manufacturers can boost in-house production capacity while benefiting from the expertise of 3D printing specialists. At our bureau, we offer a design for print consultation service where we give feedback on the printability of individual parts. Unlike other companies, we will also modify structure and orientation to improve performance and enhance individual features if needed.
To get a quote for your 3D printing project, visit the 3D Print Bureau site and upload your file. To find out more about Tri-Tech 3D’s support, visit the company’s website.
