Custom Soft Jaws Designed by AW Miller: A Rapid Prototyping Success Story

Our printers are revolutionizing machine shops. By creating custom fixtures with the Mark One and Mark Two, machinists can expand their capabilities while slashing both cost and lead time. The recent case study with reseller AW Miller demonstrates how a Markforged soft jaw can be designed and produced in record time, even when the part geometry is complex and no CAD data is available.

The Part

AW Miller challenged our printers with a 5‑axis CNC‑machined component that features multiple irregular faces and a non‑parallel surface. Conventional vices struggle to grip the part, and the face with a drilled hole cannot be machined on a standard 3‑axis machine.

To clamp the component for machining, the jaws needed to hold two irregular faces—including rounded features—at an unusual angle. Without CAD or tolerance specifications, AW Miller used a 3‑D scanner to capture the geometry, imported the scan into CAD, and carved the jaw profiles directly from the part model.

After refining the jaw design in eiger, the jaws were reinforced with Kevlar for added toughness and printed on a Markforged machine. The result: a first‑try fit that holds the component perfectly flat for machining.

The Soft Jaws

The jaws performed beyond expectations. Despite no prior testing or detailed tolerance data, they delivered an exceptional fit and reliable clamping force. AW Miller achieved this with minimal lead time and zero setbacks.

We replicated the experiment with Onyx jaws, and they matched the performance of the nylon version on the first attempt, underscoring the precision and repeatability of Markforged soft jaws.

Ready to design your own custom soft jaws? Contact us or request a demo today.