3D printed jigs and fixtures — faster and cheaper than CNC

3D printed jigs and fixtures are one of the fastest-growing applications of additive manufacturing in Danish industry. They let manufacturing companies replace expensive, slow CNC machining processes with quickly produced plastic tools in technical materials. Here's everything you need to know about using 3D printing for production aids.

What are jigs and fixtures — and what's the difference?

In industrial production, the terms jig and fixture are often used interchangeably, but technically they serve different functions:

A jig is a tool that guides another tool to the correct position — for example, a drill jig that holds a drill precisely over the correct drilling point on a part. The jig moves with the part and controls the geometry of the process.

A fixture holds a part firmly in a precise position during machining, assembly, or inspection — but doesn't guide the tool itself. A welding fixture holds two metal profiles at the correct angle while they're welded together.

In practice, both terms are used interchangeably to mean production aids that increase precision, speed, and repeatability in a production process.

Advantages of 3D printed jigs and fixtures

Price and time — the decisive difference

The traditional way to produce jigs is CNC machining in aluminum or steel. This gives high durability and precision, but at a price and lead time that makes it uneconomical for many applications. A simple aluminum jig with 2–3 positioning points typically costs DKK 3,000–8,000 and has a 3–6 week lead time from a machine shop.

The same jig 3D printed in PA6-CF costs DKK 300–1,200 and is ready in 2–5 days. That's a saving of 70–85% in material costs and an 80–95% shorter lead time. For prototype jigs and low-volume production, the math is clear.

Design freedom and fast iteration

3D printing offers design freedom that CNC can't match. Internal channels, integrated clip features, ergonomic grips, and complex positioning points can be designed and printed at no extra cost. When a jig turns out to have a flaw or the product changes, we print a new version — not a new CNC run. We have customers who iterate jig designs 3–5 times before locking the design.

Light weight

PA6-CF weighs 1.10 g/cm³ vs. aluminum's 2.7 g/cm³. A 3D printed jig typically weighs 40–60% of an equivalent aluminum jig. That reduces operator fatigue in manual assembly lines and eases the handling equipment that needs to move the jig.

Materials: PA6-CF, PETG-CF, and more

The choice of material for 3D printed jigs and fixtures depends on load, temperature, and chemical environment:

When isn't 3D printing enough?

3D printing isn't the universal answer. There are situations where metal is the right choice:

Heavy machine operations with large forces

Milling, turning, and other heavy machining processes generate cutting forces that can deform even stiff plastic materials. PA6-CF is stiff, but has 1/10 the elastic modulus of aluminum. For jigs held fixed in a CNC machine during machining, metal remains the standard.

Extreme tolerances under ±0.05 mm

FDM's tolerance is typically ±0.2 mm as standard. We can improve this to ±0.1 mm with careful calibration and material choice, but below ±0.05 mm requires jig grounding (metal inserts) or SLA/resin printing. Contact us for advice on precision jobs.

Continuous temperature above 130°C

PA6-CF's heat deflection temperature is 120–130°C. Operation above this level requires PC (polycarbonate) or a metal fixture. For welding processes that generate localized heat, we can design ventilation channels that direct heat away from the plastic material.

Design tips for 3D printed jigs and fixtures

Designing a good 3D printed jig requires understanding 3D printing's limitations and strengths. Here are the key principles we apply:

Orient for optimal strength

In FDM printing, strength is lower in the Z direction (the layer direction) than in the XY plane. Critical positioning features and load-bearing cross-sections should be designed to lie in the XY plane. A jig that's primarily loaded horizontally can be printed flat for maximum strength — a jig loaded vertically may require redesigning the layout or extra wall thickness.

Integrate metal inserts for screw connections

Screw holes in plastic wear over time. We always recommend thermal inserts (M3–M8) for screw connections that are opened and closed regularly. These are melted into the plastic with a soldering iron and provide metal-to-metal connections with a long service life. Add-on cost: DKK 15–40 per insert depending on size.

Build volume and split design

Our FDM printers have a maximum build volume of 350×350×350 mm. Large jigs beyond these dimensions are designed in two or more parts that screw or clip together. A split design is actually often an advantage — it lets you replace worn parts instead of the entire jig. We advise on the best split line on request.

Using dowel pins and holes

For precise, repeatable positioning of parts, we recommend dowel pins in standard diameters (6 mm, 8 mm, 10 mm). We print the hole with ±0.1 mm tolerance for a press fit or slide fit — and you can buy the standard pins from a local technical supplier. This gives a hybrid solution that combines 3D printing's fast production with metal's precision.

FAQ — 3D printed jigs and fixtures

What does a 3D printed jig cost at Maker Factory?

The price depends on size and material. A simple assembly jig weighing 100–200g in PETG-CF typically costs DKK 300–600 excl. VAT. A larger welding jig in PA6-CF weighing 400–600g typically costs DKK 700–1,500. We provide a fixed price in a quote within 24 hours.

Can you design the jig for us if we only have a sketch?

Yes. Our 3D design service designs your jig in CAD from sketches, measurements, or photos of the part the jig needs to fit. Design costs DKK 850/hr and a simple jig typically takes 2–4 hours to design.

What's the tolerance on your 3D printed jigs?

Standard FDM tolerance is ±0.2 mm. For critical positioning points, we can improve to ±0.1 mm with careful calibration. For positions under ±0.1 mm, we recommend metal inserts for positioning features.

Can you deliver across Denmark?

Yes. We deliver with PostNord Track & Trace across Denmark. Lead time: typically 4–7 business days including print time for PA6-CF jigs, 3–5 days for PETG/PETG-CF.

Do you print jigs in batches?

Yes. Batch production of jigs and fixtures is one of our core competencies. Multiple identical jigs are printed in parallel on the same platform for a lower per-unit price. See our 3D printing for business page for more on batch production.

What's the service life of a 3D printed jig?

PA6-CF jigs in normal assembly lines typically last 50,000–200,000 operations with no visible wear. PETG-CF jigs handle 20,000–100,000 operations. Service life depends on load, temperature, and surface contact. We have customers whose PA6-CF jigs have been running for over 2 years in daily operation.

What's the difference between a jig and a fixture?

A jig guides a tool (such as a drill) to the correct position. A fixture holds the part firmly during machining but doesn't guide the tool. In practice, both terms are used interchangeably for 3D printed production aids in general.

Also read: 3D printed templates – drill guides, stencils, and marking templates.