Tooling for Assembly: Turning Challenges into Solutions with Additive Manufacturing

Halving the weight of special tooling while simultaneously reducing costs and lead times: thanks to services provided by MadeInAdd, an engine manufacturer reaped significant benefits from using additive manufacturing for tooling production.

A vehicle isn't just composed of components meticulously built and assembled according to design specifications and engineering expertise. There's an often overlooked yet crucial aspect: tooling. These are jigs, fixtures, and assembly aids that make the production of such complex systems possible. These tools are “disposable” and are decommissioned once they've served their purpose. Therefore, producing them as economically, quickly, and efficiently as possible contributes not only to the improvement of the final product’s quality but also to cost reductions. It was based on a request from an internal combustion engine manufacturer that MadeInAdd’s specialists developed a solution capable of meeting all these requirements.

Initial Conditions

The tooling used by the customer not only supports the operator during the assembly phase, but it also enables the timing of the crankshaft relative to the camshaft. This tool is installed directly between the engine block and the cylinder head, precisely connected via four fixing points. Through this setup, the crankshaft timing is executed using two torque wrenches—one in the tool’s designated groove and the other at the end of the crankshaft—then torque is applied to rotate the crankshaft and lock it into the correct angular position. Once the operation is complete, the tool is removed, and the process moves on to the next engine.

Previously, the customer, with the help of an external supplier, manufactured these tools in metal using CNC machining. The required quantities were small, often just a few units, including some spare parts in case of breakage or failure, and delivery took about two weeks. Moreover, the component had a considerable weight of approximately 7 kg and significant dimensions (325 x 183 x 200 mm), which made handling and managing it difficult for operators.

The request to MadeInAdd, therefore, had several goals: reducing weight, costs, and lead times, all without sacrificing mechanical characteristics or precision.

Choosing the Most Suitable Technology

MadeInAdd’s first task was to gather the technical requirements to identify the most suitable technology and material. Specifically, industrial-level FDM (Fused Deposition Modeling) technology was identified as the optimal solution. This choice was particularly appealing from both a cost and technical standpoint, as it provides relatively high printing speed and good tolerances. For the material, PA6 (nylon) reinforced with continuous carbon fibers introduced during the printing process was selected. These fibers were strategically placed in areas subjected to the highest stresses, supporting the part only where necessary. Following topological optimization and initial printing tests, which took only a few days, the customer verified that all the set objectives had been achieved.

Benefits Across the Board...

The first prototype provided by MadeInAdd was immediately tested and validated in the field, replacing traditional metal components while maintaining the desired characteristics of strength and dimensional precision. The chosen material and the particular design of the new part allowed for a weight reduction of over 50%, from 7 kg to 2.5 kg, resulting in obvious benefits related to handling. Lead times were also significantly improved: the previous metal part took around two weeks for delivery, while the additive manufacturing version was delivered in under a week. This faster delivery eliminated the need for stocking spare parts, which, in case of necessity, would have halted production lines. Thanks to MadeInAdd's rapid supply chain, no spares were needed, further reducing costs related to unnecessary and expensive inventory. Overall, choosing additive manufacturing led to a 15% reduction in costs per tool produced, multiplied by fewer pieces.

…and Some Unexpected Benefits!

The topological optimization made possible by additive manufacturing resulted in very unique structures and geometries. In this case, hollowing out certain sections led to the creation of two “arms,” which—according to feedback from the client and operators—proved to be very convenient for gripping and handling the component. This was an initially unplanned benefit, but after the first part was made, it became part of the customer’s regular requirements. The results were so appreciated that the client has now changed their sourcing strategy for these tools, fully transitioning to MadeInAdd’s consultancy and supply chain, delegating both design and production. This has streamlined their supply chain and production management processes.

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