Not every component is easy to hold for CNC machining. For one of our recent jobs, the part had an unusual shape that made conventional workholding difficult, so we designed and produced a purpose-made two-part 3D-printed jig.
The printed sections were shaped around the component, creating dedicated support areas that made the part easier to position for the required CNC operation. It is a straightforward example of 3D printing solving a genuine workshop problem.
The CNC workholding challenge
Standard vices, clamps and flat parallels work well for regular components. Problems arise when a part has curved, angled or irregular surfaces that do not sit naturally within a normal machining setup.
For this job, the unusual geometry meant the component needed a support designed specifically around its shape. The aim was to hold and locate the part without relying on unsuitable flat supports.
Designing the two-part printed jig
We designed the jig as two separate printed sections, each incorporating shaped areas to suit the component. The finished design includes substantial support faces, a central slot and a circular opening as part of its job-specific geometry.
Creating the jig digitally allowed the shape to be produced without the additional machining operations that would normally be required for a conventional fixture with similarly irregular geometry.
Using the jig during machining
Once printed, the two sections were used to help position and support the component for the CNC operation. The jig was designed for this particular part rather than being a general-purpose workshop fixture.
Purpose-made tooling like this can be useful for one-off jobs, prototypes and smaller production runs where producing a more complex metal fixture may not be the most practical option.
Why 3D printing suited this job
3D printing makes it possible to produce jigs and supports directly from a digital design. Unusual profiles, slots, recesses and different support heights can all be incorporated into a single printed component.
The design can also be stored and printed again if the job returns. If the component or machining setup changes, the digital model can be modified without starting the entire fixture design again.
Need a custom jig, fixture or printed part?
Wards Additive works alongside the machining and fabrication capabilities of Wards Welding & Fabrications Ltd. This allows us to design printed tooling around genuine workshop and manufacturing requirements.
If you have an awkward component or a production problem that could benefit from a custom jig, support or fixture, send us a photograph or drawing and explain what you need the part to do.
