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

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.

- Identify the need, design the CAD model, and print the first prototype on Thursday.
- Refine the design based on test feedback and produce the second iteration on Friday.
- 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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