An automotive assembly fixture has curvy, ergonomic handles.

Manufacturing Tooling

Streamline production and customize on the fly

Quick, low-volume tooling and custom fixtures give manufacturers the flexibility to embrace more opportunities, act faster and shrink the cost and risk associated with traditional production.

Modular Fixtures & Components

Overview

A modular fixturing system is a versatile alternative to a single–purpose, dedicated fixture. Constructed from a kit of interchangeable components, the modular fixture is easily reconfigured for any workholding application. When not in use, the fixture can be dismantled for convenient storage.

Modular systems are ideal for intermittent or one–time use. They are commonly used to:

  • Stage parts for CMM inspections
  • Hold work pieces during machining
  • Position parts when bonding or assembling

For these applications, the modular system saves time and reduces cost.

While the majority of the modular fixture is constructed from standard components, the interface is custom made with FDM technology on a Fortus 3D Production System. At each support point, an FDM contact element acts as the transition from the part’s surface to the fixture’s grid plate, pillar or beam. These contact elements can be manually designed in CAD, but this design effort may take more time than that to construct the FDM elements.

The Magics RapidFit module provides a faster and easier way to create the STL files for the custom FDM elements. This software, created by Materialise, automates the digital design process. With just a few mouse clicks, the files are ready for building on a Fortus system. Just a few hours later, the fixture is assembled and ready for use.

Process

1. Design Fixture:

Option A - Use CAD program
Option B - Use Materialise RapidFit

  1. 1. Import the STL file of the part to be fixtured into Magics RapidFit. Also, import or create the files for the modular components of the fixture.
  2. 2. Begin the design by positioning the part, grid plate, pillars and beams in the desired configuration.
  3. 3. To create the custom contact elements, select the fixture support points and specify the type of contact to use and the direction to the grid plate. The RapidFit software will automatically create the contact elements and label each with a location and part name. RapidFit also documents the assembly plan.

2. Manufacture Fixture Components:

Import the STLs of the contact elements into Insight and prepare them for building. All Fortus materials and build styles may be used. However, ABS–M30, PC, PC-ABS with soluble supports and a solid fill are recommended.

When the build is complete, simply remove the support structures and proceed to assembly.

3. Construct Fixture:

Gather the grid plate, pillars, beams and FDM components. Following the assembly instructions, place the FDM components on the beams and pillars, and connect the beams to the grid plate. The modular fixture is now ready for its inspection or manufacturing application.