Ryan Lodermeier
BMW jigs and fixtures
BMW has realised a 57% cost saving with 3D printed jigs and fixtures.
Jigs, fixtures and other tools utilised in manufacturing can be the backbone of a production floor. Successful repeatability, reliability and quality often relies on simple manufacturing aids that provide guidance and security during crucial assembly and inspection operations.
Jigs and fixtures can be off-the-shelf, but often manufacturers will custom design their own manufacturing aids for unique operations to their products. Additive manufacturing (AM) eliminates cost, lead time and design barriers to adopt manufacturing aids on the shop floor. AM can deploy jigs and fixtures where they previously could not exist due to several key advantages:
Complex Design
The most obvious benefit of 3D printing across all applications is the freedom of design possible with an AM process. Freed from the limitations of injection moulding or machining operations, 3D printing opens nearly endless opportunities for tool configuration. Common conventional design considerations, like irregular profiles, contours or number of machine set ups are no longer relevant when designing parts for 3D printing.
Component Consolidation
With the complexity available with AM, you can lessen or eliminate the costs and long lead times associated with assembly operations. Tools previously engineered with multiple components requiring assembly and fits, can be redesigned as one contiguous component, saving post-build labour.
Better ergonomics
Consolidation and freedom of design allows for manufacturing aids with improved handling and ease of use. Conventionally manufactured tools produced with design restraints can be heavy and clunky, adding strain to the labour force and time on the line. Jigs and fixtures without basic ergonomic functionality can have a huge impact on the bottom line, including flawed units, significant down time on the floor and worker discomfort. 3D printed manufacturing aids are an effective method for incorporating contours and organic shapes that increase safety, efficacy and comfort.
Weight Reduction
Another comfort and safety advantage found in 3D printed jigs and fixtures is weight reduction. Strong plastics are an excellent alternative to conventional metal cutting processes, and AM has delivered significantly lighter tools to production workers involved in assembly and fixture work. Tools that are lighter weight increase productivity; cumbersome metal tools that have be moved across the production floor are less likely to be used. A lightweight, optimised manufacturing aid can have the same functionality while providing better ease of use.
Customisation
AM can reduce costs, lead times and design barriers.
Freedom of design opens greater control over tasks and further enables ergonomic support for workers, resulting in higher accuracy when performing tasks. Instead of designing for manufacturability, engineers can tailor a manufacturing aid for the task or employee utilising it.
Get your FREE print subscription to TCT Magazine.
Exhibit at the UK's definitive and most influential 3D printing and additive manufacturing event, TCT 3Sixty.
Digital Inventory
3D printing jigs and fixtures is best suited for lower quantities runs. The easy accessibility of a digital file allows you to produce aids as needed. This “digital inventory” is always available and allows you to update and redesign tools quickly and effortlessly.
No Machining
If a part is designed for a tolerance +/- 0.005” or +/-0.0015 inch over inch, whichever is greater, AM can deliver the part straight off the machine. The complementary partnership of additive and conventional manufacturing can enhance the benefits that can be achieved with either process on its own. However, there are many instances in which no machining is required for AM jigs and fixtures, which saves valuable time and money.
Cost reduction
Ultimately, all the above benefits result in a reduction in cost compared to conventionally manufactured manufacturing aids. For example, BMW updated aluminum fixtures utilised in assembly and testing bumper supports with 3D printed ABS thermoplastic fixtures. The new 3D printed fixtures are 72% lighter than the previous fixtures and have improved productivity and accuracy thanks to improved ergonomics that are far less taxing on the assembler. By switching, BMW has realised a 58% saving in cost per fixture and a 92% increase in faster lead time.
