3D Printing for Manufacturing Tooling
//Cut Lead Times, Reduce Costs, and Bring Tooling Production In-House
Can 3D Printing Replace Your Machined Jigs, Fixtures, and Production Tools?
For many applications, yes. Industrial 3D printing technologies including FDM, SLA, and SLS are now proven, production-ready alternatives to machined tooling for jigs, fixtures, assembly aids, inspection tools, and end-of-arm tooling. Manufacturers across the Midwest are bringing tooling production in-house, reducing lead times from weeks to hours and cutting per-tool costs by 70 to 90 percent compared to traditional machining and outsourcing.
AdvancedTek has supported manufacturers across Minnesota, Wisconsin, Iowa, Illinois, Kansas, Missouri, Nebraska, North Dakota, and South Dakota for more than 30 years. Our application engineers and sales professionals help facilities evaluate which 3D printing technology and material is the right fit for each tooling application.
What Is 3D Printed Manufacturing Tooling?
Manufacturing tooling refers to the specialized tools, guides, and fixtures used in production environments to hold, position, guide, or inspect parts during assembly, machining, welding, or quality control. Traditionally these tools are machined from aluminum or steel, a process that is expensive, time-consuming, and inflexible when design changes are required.
3D printed manufacturing tooling produces these same tools directly from a CAD file. Depending on the application, FDM thermoplastics, SLA resins, or SLS nylon powders can each be the right choice, selected based on the mechanical demands, temperature requirements, surface finish needs, and geometry of the specific tool. When a design needs to change, you update the file and print the next version.
Which 3D Printing Technology Is Right for Manufacturing Tooling?
Not every tooling application calls for the same technology. Here is how the three primary processes compare for manufacturing tooling use cases.
FDM (Fused Deposition Modeling)
FDM uses engineering-grade thermoplastics to produce rugged, load-bearing tools with material properties suited to demanding production environments. It is the most widely adopted technology for structural jigs and fixtures, end-of-arm tooling, welding fixtures, drill guides, and composite layup tooling. FDM parts are strong, chemically resistant, and available in a broad material range from general-purpose ABS to high-performance ULTEM.
Best for: high-stress fixtures, EOAT (end-of-arm tooling), welding fixtures, composite tooling, large-format production aids.
SLA (Stereolithography)
SLA uses photopolymer resins cured by light to produce parts with fine surface finish, sharp feature resolution, and tight dimensional tolerances. SLA is well-suited for inspection gauges, alignment aids, master patterns for soft tooling, and light-duty fixtures where cosmetic quality and precision matter more than impact resistance. Modern engineering resins extend SLA’s functional range into stiffer, more heat-resistant applications. AdvancedTek offers SLA platforms including the Formlabs Form 4 and Form 4L and the industrial-scale Stratasys Neo Series.
Best for: inspection fixtures, CMM gauges, alignment aids, master patterns, presentation tooling.
SLS (Selective Laser Sintering)
SLS uses a laser to sinter nylon powder into strong, isotropic parts without support structures. This makes SLS particularly well-suited for complex fixture geometries, undercut features, and tooling that would require extensive post-processing on FDM systems. SLS nylon parts offer excellent toughness and chemical resistance for production environments.
Best for: complex geometry fixtures, functional nylon tooling, low-volume production aids requiring no support removal.
Types of Manufacturing Tooling
Assembly Jigs and Fixtures
Custom tools that position and hold parts in precise alignment during assembly operations. FDM thermoplastics are the standard choice for load-bearing structural fixtures. SLA resins are suited for lightweight alignment aids where surface finish and precision are the priority. Both technologies produce fixtures faster and at lower cost than machining, with the ability to iterate designs the same day.
Inspection Fixtures and CMM Tooling
CMM fixtures and go/no-go gauges produced with additive manufacturing eliminate the cost and lead time of machined inspection tooling. FDM fixtures can be printed as a single piece, eliminating the dimensional error that accumulates in multi-piece built-up fixtures. Published data from Oreck Corporation documents a reduction in inspection time from 30 days to one day after switching to 3D printed CMM fixtures. For high-detail gauges requiring smooth contact surfaces and tight tolerances, SLA resins including Rigid 10K are a strong option for lower-stress measurement applications.
End-of-Arm Tooling (EOAT)
Robot end-of-arm tools are among the most widely adopted 3D printing applications in industrial manufacturing. Printed EOAT is significantly lighter than machined aluminum equivalents, reducing robot payload requirements and cycle time. A Midwest manufacturer working with AdvancedTek replaced traditionally manufactured grippers with FDM-printed alternatives and documented the ability to have a new end-of-arm tool complete and operational on the robot within a single day, compared to weeks for traditionally manufactured tooling.
Welding Fixtures and Positioning Tools
Custom welding fixtures hold components in precise position during welding operations. FDM-printed welding fixtures can be produced in hours for one-off or low-volume applications and can be redesigned and reprinted immediately when part geometry changes.
Drill Guides and Machining Aids
Drill guides and machining aids produced with FDM thermoplastics guide cutting tools with sufficient accuracy for many production drilling and machining applications, particularly in aerospace and automotive assembly environments.
Composite Layup Tooling
FDM is a proven technology for producing layup tools, molds, and mandrels used in composite manufacturing. High-temperature materials including ULTEM 1010 withstand the elevated temperatures required for autoclave cure cycles, making 3D printed composite tooling a practical alternative to machined aluminum and epoxy tooling board for low-volume or prototype composite parts.
Master Patterns and Soft Tooling
SLA resin printing produces master patterns for urethane casting, vacuum forming, and silicone mold making with surface quality that rivals machined tooling. The Form 4L’s large build volume of 35.3 x 19.6 x 35 cm accommodates full-size patterns for automotive trim pieces, enclosures, and other large tooling masters.
Why Manufacturers Choose 3D Printed Tooling
Lead Time Reduction
Machined tooling typically requires one to six weeks from design to delivery, including quoting, programming, machining, and finishing. 3D printed tooling is produced in hours to days directly from a CAD file. For facilities running lean operations or responding to design changes, this difference is a meaningful operational advantage.
Significant Cost Reduction for Short-Run and Custom Tooling
For custom, low-volume, or frequently revised tooling applications, 3D printing is dramatically more cost-effective than machining. The cost advantage is largest for complex geometries, where machining setup costs are highest.
Lighter Tools, Easier Handling
3D printed thermoplastics and resins weigh significantly less than aluminum or steel. Lighter fixtures reduce operator fatigue on assembly lines and reduce payload requirements for robotic end-of-arm applications, extending robot service life and improving cycle time.
Design Freedom Without Machining Constraints
3D printed tooling can incorporate features that are difficult or impossible to machine economically: internal channels, lattice structures for weight reduction, conformal contact surfaces, and integrated assembly features. When a design needs to change, the next version can be on the printer the same day.
On-Demand Production and Digital Inventory
When a tool breaks or wears out, it can be reproduced on demand from the original CAD file. Facilities with in-house 3D printing eliminate tooling inventory costs and the production disruption caused by waiting on replacement parts from an external machine shop or service bureau.
Common Materials for 3D Printed Manufacturing Tooling
FDM Thermoplastics
ABS and ASA: Cost-effective materials for light-duty assembly aids, ergonomic handles, and general-purpose fixtures in ambient temperature environments.
Nylon 12 and Nylon 12CF: High toughness and chemical resistance for fixtures exposed to coolants, lubricants, or mechanical wear. Carbon fiber-filled Nylon 12CF offers the highest stiffness-to-weight ratio of any FDM thermoplastic, with sufficient strength to replace metal in many fixture and EOAT applications at significantly lower weight.
Polycarbonate (PC) and PC-ABS: High impact strength and heat resistance for tooling used in elevated temperature environments or applications requiring dimensional stability under load.
ULTEM 9085 and ULTEM 1010: High-performance polyetherimide thermoplastics for the most demanding tooling applications. ULTEM 1010 is rated for autoclave cure cycles and is used in composite tooling and high-temperature inspection fixtures. ULTEM 9085 carries FAA-recognized flame, smoke, and toxicity ratings for aerospace tooling applications.
SLA Resins
Formlabs
Rigid 10K Resin: A highly glass-filled engineering resin with excellent stiffness and dimensional stability. Well-suited for jigs, fixtures, and inspection gauges requiring tight tolerances and resistance to deformation under load.
Tough 1500 Resin: Simulates the behavior of polypropylene, offering flexibility and impact resistance. Appropriate for snap-fit fixtures, clips, and assembly aids that need to flex without breaking.
High Temp Resin: Rated for heat deflection up to 238 degrees Celsius under load. Suitable for tooling used in elevated temperature environments including thermoforming aids and heated assembly fixtures.
Grey Pro Resin: A general-purpose engineering resin with low creep, moderate flexibility, and excellent surface finish. Suitable for master patterns, soft tooling molds, and presentation-grade fixtures.
Explore all Formlabs SLA printers available through AdvancedTek.
Stratasys
Neo Series Resins: The Stratasys Neo Series runs an open material system compatible with Somos resins and other commercially available 355 nm SLA materials, giving industrial users flexibility to select the best resin for each application. For tooling applications, Somos WaterShed XC 11122 is the most widely used option — an ABS-like resin with strong water and chemical resistance suited for functional tooling, master patterns, and production aids. Somos DMX-SL 100 is the choice for demanding composite tooling applications requiring high toughness and durability. View Neo-featured SLA materials at AdvancedTek.
SLS Nylon
Nylon 12: The most widely used SLS material for manufacturing tooling. Excellent dimensional accuracy and surface detail make it the standard choice for precision fixtures, jigs, and inspection tooling. Strong, isotropic, and chemically resistant for demanding production environments.
Nylon 12 GF: A glass-filled variant of PA 12 with significantly higher stiffness and resistance to creep under sustained load. The better choice when a fixture needs to hold its shape under continuous pressure or in elevated temperature environments.
Nylon 11 CF: Carbon fiber-reinforced nylon with the highest stiffness-to-weight ratio of any Fuse 1+ 30W material. The right choice for EOAT and structural tooling applications where reducing weight without sacrificing rigidity is a priority.
See the Formlabs Fuse 1+ 30W, AdvancedTek’s recommended in-house SLS platform for Midwest manufacturers.
Industry Examples
J.W. Speaker — Manufacturing Fixtures
J.W. Speaker, a Midwest manufacturer of high-performance LED lighting systems, brought fixture production in-house using FDM with carbon fiber-filled nylon to produce large-scale automation pallets and photometry fixtures. The transition delivered 89% faster production compared to outsourcing (nine hours versus approximately 80 hours) and 78% faster than in-house machining (nine hours versus one week). Cost savings totaled $50,000 to $60,000 on automation pallet production and $10,000 to $15,000 on photometry fixtures. Source: J.W. Speaker use case
General Motors — Overhead Conveyor Tooling
GM engineers replaced aluminum overhead conveyor risers with FDM parts printed in carbon fiber-filled nylon. The 3D printed components delivered a 32% weight reduction compared to aluminum and a 72% weight reduction compared to steel, while cutting lead time from nine weeks for metal risers to two weeks, a reduction of approximately 78%. The lighter components also reduced conveyor system wear and simplified on-site spare parts production. Source: General Motors case study
General Motors — Assembly Line Hemming Tool
In a separate application, GM 3D printed an assembly line hemming tool using ASA thermoplastic instead of machining it from aluminum billet. The printed tool was completed in three weeks versus 10 to 13 weeks for the machined aluminum alternative, a lead time savings of more than 70%. Part weight dropped from 75 pounds to 33 pounds, eliminating the need for lift assistance and improving operator ergonomics. Total cost was reduced by 74%. Source: General Motors case study
Oreck Corporation — CMM Inspection Fixtures
Oreck’s quality assurance team uses 3D printed CMM fixtures to inspect injection-molded parts before production. Previously, machined fixtures required seven to ten days of lead time, and the full inspection process, including fixture setup and CMM programming, took three to four weeks to complete. After switching to FDM-printed fixtures, the entire process was reduced to one day. Source: Stratasys inspection fixtures page
Frequently Asked Questions
Can 3D printed jigs and fixtures replace machined metal tooling?
For many production tooling applications, yes. FDM thermoplastics including carbon fiber-filled nylon and high-performance polyetherimide materials produce tools with sufficient strength, dimensional accuracy, and durability for assembly, inspection, and end-of-arm tooling applications. For lighter-duty applications requiring fine surface finish or tight tolerances, SLA resins are a strong complement. Metal tooling remains the appropriate choice for applications requiring metal-level strength, temperatures beyond the capability of available polymers, or tolerances tighter than additive manufacturing can achieve.
Which 3D printing technology is best for manufacturing tooling?
It depends on the application. FDM is the standard choice for load-bearing, high-stress tooling including EOAT, welding fixtures, and composite layup tooling. SLA is the right choice for inspection gauges, alignment aids, master patterns, and precision light-duty fixtures. SLS nylon is the best option for complex geometry tooling that requires no support structures. Many facilities benefit from having more than one technology available, using each for the applications it is best suited to.
What materials are best for 3D printed manufacturing fixtures?
For high-stress fixtures and EOAT, carbon fiber-filled nylon offers the best strength-to-weight ratio and is the most common metal-replacement material in FDM tooling. For elevated temperature environments, polycarbonate or ULTEM-based materials are appropriate. For precision inspection tooling with smooth contact surfaces, Rigid 10K SLA resin is a strong option. For general-purpose fixtures, ABS and ASA are cost-effective starting points.
How long does it take to 3D print a manufacturing fixture?
Most FDM manufacturing fixtures are produced in four to twenty-four hours, depending on part size and complexity. SLA resin parts on modern platforms are typically completed in under two hours for standard-size tooling. SLS nylon parts are generally available within 24 hours. All three compare favorably to the one to six week lead time for traditionally machined tooling.
Does AdvancedTek offer application support for 3D printed tooling?
Yes. AdvancedTek’s application engineers and sales professionals work with manufacturers across the Midwest to evaluate tooling applications and select the right technology and material before you commit to a 3D printing system. AdvancedTek offers FDM, SLA, SAF, PolyJet, P3 DLP, SLS, and DMLS platforms and can help identify which approach is the right fit for your production environment.
Talk to an AdvancedTek Additive Manufacturing Expert
If you are evaluating 3D printed tooling for your facility, AdvancedTek’s sales representatives can help you identify the right applications, select the right technology and materials, and run the numbers on lead time and cost savings for your specific production environment.
Request a consultation: advancedtek.com/contact-us Call us: 800-482-9005
AdvancedTek is a Midwest additive manufacturing partner serving organizations across manufacturing, medical, education, and engineering in Minnesota, Wisconsin, Iowa, Illinois, Kansas, Missouri, Nebraska, North Dakota, and South Dakota. As an authorized reseller for Stratasys, Formlabs, and EOS, AdvancedTek provides the equipment, materials, software, and application expertise companies need to adopt, scale, and optimize additive manufacturing in-house.