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Carl Calabria’s Carbon‑Fiber Jig for Precise Composite Spool Tensioner Alignment

Carl Calabria’s Carbon‑Fiber Jig for Precise Composite Spool Tensioner Alignment
During yesterday’s production review on October 22, engineers noted that composite spool tensioners on the new Mark One 3‑D printers were not consistently aligned. While the misalignment does not affect print performance, it detracts from the printer’s overall aesthetic quality. In keeping with our philosophy that every component matters—even those rarely seen—Carl Calabria set out to design a simple, robust jig that guarantees proper tensioner placement.

Carl leveraged OnShape to create the initial CAD model, then imported it into Eiger, the MarkForged proprietary software. To withstand the inevitable drops and bumps in a busy production environment, the jig was reinforced with continuous carbon fiber, providing both stiffness and durability without adding excessive weight.

Carl Calabria’s Carbon‑Fiber Jig for Precise Composite Spool Tensioner Alignment
  1. Identify the need, design the CAD model, and print the first prototype on Thursday.
  2. Refine the design based on test feedback and produce the second iteration on Friday.
  3. Install the jig at the factory for routine use starting Monday.

Modelled by Carl Calabria, Senior Application Engineer at MarkForged.

Download the Thingiverse files for the tensioner jig (STL and MFP) and start aligning your printers today.

Composite Spool Tensioner Jig Specifications
Size: 144.44 mm × 79.88 mm × 4 mm
Estimated print time: ~3 h 33 m
Nylon cost: ~$3.16
Carbon fiber cost: ~$3.45
Download: STL, MFP

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