How 3D Printing Transforms Jigs & Fixtures: 6 Proven Ways to Boost Production Efficiency

Jigs, fixtures and grips are indispensable, yet often overlooked, tools that underpin every manufacturing line. Their quality directly determines productivity, safety and product consistency.

In recent years, industry leaders such as Volkswagen, Boeing, and Jabil have turned to 3D printing to produce these tooling aids, unlocking a new era of lean manufacturing.

What tangible benefits does 3D printing bring to the fabrication of jigs and fixtures?

The importance of jigs and fixtures

Optimising production hinges on reliable tooling. Jigs and fixtures ensure that each part is produced with high precision, repeatability and minimal waste, while also protecting workers from repetitive strain.

They achieve this by:

• Reducing scrap and rework
• Enhancing process accuracy and repeatability
• Lowering the skill threshold required to operate them
• Boosting overall productivity

3D‑Printed Tools: Breaking with Tradition

Between 2017 and 2021, the share of companies using additive manufacturing for tooling grew from 30% to 57%—a clear sign of the industry’s shift.

Conventional methods—CNC machining, welding, and hand assembly—can consume days or weeks, involve complex planning, and demand highly skilled operators. The result: long lead times, high costs, and limited flexibility.

By contrast, 3D printing allows on‑demand production of jigs and fixtures at a fraction of the material cost, and supports rapid iteration.

Why 3D Printing?

1. Faster lead times

Digital manufacturing turns a CAD file into a physical part in hours. Volkswagen Autoeuropa reported an 89% time saving using 3D‑printed tooling, while Stratasys research cites up to 90% lead‑time reduction.

Speed also means designers can prototype multiple iterations in a single day, freeing engineering teams from lengthy supplier cycles.

2. Reduced costs

In‑house 3D printing eliminates outsourcing fees and inventory holding costs. Liberty Electronics cut the cost of a custom tool by 85% after switching to in‑house additive manufacturing. Because the process is additive, material waste is virtually eliminated.

3. Improved ergonomics

Lightweight, high‑performance materials lower the physical burden on workers. Eckhart, for example, used a 3D‑printed jig that attaches to a vehicle’s windshield, enabling consistent wiper blade installation in 45 seconds and eliminating rework.

4. Greater material variety

From advanced polymers like PEKK and ULTEM to composites and rubbers, 3D printing offers a spectrum of materials with tailored mechanical, chemical, and thermal properties—ideal for high‑performance tooling.

5. Improved performance

AM lets designers embed serial numbers, fabrication dates, and other metadata directly into the part, streamlining inventory tracking. Complex geometries that would be impossible to machine can now be printed in a single build.

6. Customisation

Custom, complex shapes—such as surgical guides or bespoke assembly aids—can be produced effortlessly. In the medical field, 3D‑printed surgical guides reduce operative time and enhance patient outcomes.

3D Printed Jigs and Fixtures in Action

Manufacturing

Jabil

With over 100 facilities worldwide, Jabil leverages Ultimaker AM systems to produce jigs and fixtures. The Auburn Hills plant demonstrates cost reductions of up to 30% and lead‑time cuts of 80%, while maintaining high customer satisfaction.

Aerospace

Moog Aircraft Group

Moog’s use of FDM to print CMM fixtures slashes lead time from four‑six weeks to roughly 20 hours and reduces costs from £2,000 to a few hundred pounds.

Boeing

In 2016, a partnership with Oak Ridge National Laboratory produced a record‑setting 3D‑printed trim‑and‑drill tool for the 777X in just 30 hours, using the Big Area Additive Manufacturing (BAAM) machine.

Automotive

BMW

BMW’s 3D‑printed hand tools weigh 72% less than their metal counterparts, enhancing worker ergonomics and tool performance.

Renault Sport F1

Renault switched from CNC‑machined exhaust jigs to SLA‑printed versions, enabling the production of 15 jigs overnight and eliminating the week‑long build cycle.

How to Maximise the Impact of 3D‑Printed Jigs & Fixtures

Optimise Tool Design

Start with a design that exploits the freedom of additive manufacturing—incorporating features that would be impossible or costly with subtractive methods. Automated design tools from Trinckle and Stratasys’ Fixture Generator can reduce design time from hours to minutes, delivering both speed and cost savings.

Digitalise Inventory for Easy Reordering

Replace ad‑hoc email requests and shared folders with a digital catalogue that links 3D design files to production requirements. Integrating this catalogue with an additive MES system streamlines ordering, scheduling, and traceability.

The Future of Tooling is 3D Printing

While jigs and fixtures may seem routine, they are pivotal to manufacturing excellence. Additive manufacturing offers unparalleled speed, cost efficiency, and design flexibility—enabling firms to produce bespoke tooling at scale. Companies that adopt 3D printing today will reap the benefits of smoother, more responsive production lines tomorrow.