What are the best ways to use 3D printing for custom jigs and fixtures in manufacturing?

Using filaments having carbon fibre content provide better strength to the fixture parts. When printing the parts the area where maximum force distribution want to analyse first and the print orientation would finalise according to that to prevent the failure.

Get familiar with the terms used to describe material strengths and characteristics. For example, stiffness in the form of yeild strength but limited deflection, can mean a part is brittle. In tool holding and jigs, having a little flexibility prior to a part failing is often preferable to an overy stiff part the cracks or breaks in half when stressed. As a comparison, PVA, PLA and carbon filled ABS are very stiff, but not durable, while ASA, Nylon and Polycarbonate are very durable, but less stiff. Polycarbonate has highest heat resistance, (and high print temps), while ASA, Nylon and ABS are very good in heat tolerance, while PLA and many carbon filled materials are at the low end. Know the materials well and match them to the end use.

Layer direction is a big factor in 3D part strength. Consider the finished part like wood, where the strength along the grain is very high, and accross the grain weak. This may mean that the jig or fixture is made up of parts that are fused together, to orient strain and print playering direction for optimal performance. This means that fixtures designed in CAD for 3D Printing may be assemblies of components, rather than one monolythic part printed as a single lump. Similar to plywood, mixing layer directions can produce exceptionally strong parts, in the intended load directions. This means knowing up-front what stress the fixture will be exposed to and designing around those loads.

It is entirely possible to not only add components to a 3D printed part after the print is created, but also integrated into the part during the print process itself. Fasters, sensors, magnets, even reinforcing metal structures can be integrated during the print process by creating a cavity, pasuiing the print process to insert the component, then continuing the print to bury the insert inside the finished end product. Integrating conductive paths, optical features, electronics, optical fibers, and other technology within a print can also be acconmplished by making capsules of a known shape, that hold components inside, that are then inserted during or after a print is complete.

Sehr wichtig hat sich in meiner Arbeit herausgestellt, die Konstrukteure mit den M?glichkeiten vertraut zu machen, die 3D-Druck an neuen Gestaltungsm?glichkeiten für Bauteile bietet. Erst wenn die Konstrukteure verstehen, was im Gegensatz zu konventionellen Fertigungsmethoden m?glich ist k?nnen sie ihre Bauteile und Baugruppen optimieren und in einem zweiten Schritt weitere Funktionalit?ten und Funktionen integrieren. In der Automatisierungstechnik bieten sich viele M?glichkeiten, wie z.B. Greifersysteme mit integrierten Sensoren, komplexe Aufnahmesysteme, Roboterbauteile mit Sensorik an, damit aus einem 3D-Druckteil ein komplexes System wird. Das muss aber in den K?pfen der Konstrukteure verankert sein um die Vorteile zu generieren.

For a durable jig/fixture, prioritize proper storage, control the environment, and provide user training to ensure longevity and reliability. If a jig/fixture is irreparably broken, dispose of it to prevent further use.

3D printing of any part requires a unique set of knowledge and understanding of the print processes being used, the material characteristics, strengths and weaknesses. I have found that designing parts to be 3D printed results in adjustments to how the parts are designed to enhance performance of the finished part, that is different than other methods of production. No draft angles are needed, but heavier wall thickness is often needed. My strongest parts, from DRO mounts on my lathe, to fenders on a motorcycle, are made from many parts with layer direction considered for strength, solven welded together.

It's a good practice to label jigs or fixtures in both production and R&D settings. A well-designed label should clearly indicate the purpose of the jig/fixture and its design revision, which can be crucial, especially when revisions are subtle or not immediately evident.