Custom Tooling
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FDM 3D printing has emerged as a game-changer in industrial tooling, enabling companies worldwide to produce custom jigs, fixtures, molds, and functional prototypes faster and cheaper than ever. By bypassing traditional CNC machining or injection molding, manufacturers now design lightweight, high-strength tools tailored to specific workflows—saving weeks of lead time and thousands in costs. From aerospace composites to automotive assembly lines, FDM democratizes tooling production, empowering even small workshops to innovate like industry giants.
Customization: Design snap-fit alignment guides, ergonomic handles, or multi-functional brackets that integrate directly with existing machinery.
Speed: Print tools in hours instead of waiting weeks for outsourced parts.
Cost: A $50 spool of filament replaces $500+ machined metal components.
Complexity: Create lattice structures for weight reduction or internal channels for cooling/heating without machining constraints.
Polymaker’s Fiberon™ series combines fiber reinforcement, heat resistance, and warp-free printing to meet rigorous industrial demands.
Properties:
250°C+ HDT (heat deflection temperature) for autoclaves, engine bays, or high-temp molding.
Chemical resistance to fuels, acids, and solvents.
Metal-like stiffness with 10% carbon fiber reinforcement.
Applications:
Composite layup tools for aerospace wings.
Injection mold inserts for low-volume production.
Properties:
215°C HDT and exceptional rigidity with 20% carbon fiber.
Warp-Free™ technology for dimensional stability on open-frame printers.
Applications:
Welding jigs, robotic end-effectors, and CNC alignment brackets.
Properties:
25% glass fiber for impact resistance and durability.
191°C HDT for thermoforming or heat-assisted assembly.
Applications:
Sanding jigs for automotive body panels.
Composite trimming fixtures.
Properties:
Electrostatic discharge (ESD) protection for electronics assembly.
High toughness for repetitive use.
Applications:
PCB testing fixtures, sensor mounts, and conveyor guides.
Companies across industries leverage Fiberon™ to solve unique challenges:
Aerospace: Print autoclave-resistant composite tools for wing spar layups.
Automotive: Produce heat-resistant injection mold inserts for prototype car interiors.
Consumer Electronics: Design ESD-safe alignment jigs for smartphone assembly lines.
Polymaker’s Fiberon™ line has become a staple for manufacturers prioritizing speed-to-market and cost efficiency, with adoption spanning Fortune 500 suppliers to boutique workshops. For example, automotive tier-1 suppliers use PA6-CF20 to print robotic arm fixtures that withstand 200°C paint-drying ovens, while drone manufacturers rely on PPS-CF10 for lightweight composite molding tools.
Design: Optimize tools in Fusion 360 with lattice infills or embedded mounting points.
Print:
PPS-CF10: 310–350°C nozzle, 80°C bed, enclosed chamber.
PA6-GF25: 280°C nozzle, 80°C bed, no enclosure needed.
Post-Process: Anneal parts for enhanced heat resistance or coat with epoxy for vacuum integrity.
A European aerospace supplier replaced aluminum trimming jigs with PA6-GF25 prints, reducing weight by 60% and cost by 85%. The 3D-printed fixtures endured 500+ cycles of CNC trimming without failure, demonstrating Fiberon™’s durability.
Performance: PPS-CF10 outperforms aluminum in heat resistance for many short-run tooling applications.
Accessibility: Warp-Free™ technology allows printing on standard FDM printers.
Sustainability: PETG-rCF08 uses recycled carbon fiber, reducing waste.
As continuous fiber reinforcement and high-temp composites evolve, FDM will enable end-use tools like hydroforming dies and composite mandrels. Polymaker’s Fiberon™ line exemplifies this shift, offering industrial-grade materials that redefine what’s possible on desktop printers.
By merging FDM’s flexibility with Fiberon™’s engineered performance, manufacturers worldwide are proving that the right tool isn’t just a purchase—it’s a print away.
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