3D Printed Jigs, Fixtures and Grippers: A Smarter Way to Support Production

In any manufacturing environment, efficiency and consistency matter. Even small improvements in how parts are handled, assembled or inspected can have a noticeable impact on output and quality. That’s where jigs, fixtures and grippers come in.

Traditionally, these tools have been machined from metal or moulded from plastics. While effective, they can be expensive, slow to produce, and difficult to modify once in use. 3D printing offers a more flexible approach.

What Are 3D Printed Jigs, Fixtures and Grippers?

Jigs, fixtures and grippers are tools used to guide, hold or position parts during manufacturing and automated processes.

• Jigs typically guide a tool, such as a drill or cutter.
• Fixtures hold a part securely in place during operations like assembly, inspection or machining.
• Grippers are used in automated systems to pick up, move and place parts during production.

Together, they play a critical role in improving repeatability, reducing human error, and increasing efficiency across both manual and automated workflows.

The Limitations of Traditional Tooling

Conventional jigs, fixtures and grippers are often designed for long-term use, which makes sense in high-volume production. But this approach comes with trade-offs:

• Long lead times for design and manufacturing
• High upfront costs, even for simple tools
• Limited flexibility once the tool is produced
• Difficult and costly to update when designs change

For many manufacturers, especially those working with low to medium volumes or frequent design iterations, this can slow things down.

How 3D Printing Changes the Equation

3D printing allows these parts to be produced faster, with fewer constraints, and at a lower cost for small to medium volumes.

This opens up new possibilities for how tooling is designed and used on the production floor.

• Faster Turnaround – Tools can be designed, printed, and deployed in days rather than weeks.
• Design Freedom – Complex geometries, internal features, and ergonomic shapes can be created without additional cost or tooling.
• Easy Iteration – If something needs to change, the design can be updated and reprinted quickly without starting from scratch.
• Cost Efficiency – For low-volume or frequently changing applications, 3D printing removes the need for expensive machining or tooling investment.

Where 3D Printed Jigs, Fixtures and Grippers Add Value

The benefits are practical and immediate, particularly in environments where flexibility matters.

• Assembly Aids – Custom fixtures can help align parts, hold components in place, or simplify repetitive tasks. This reduces assembly time and improves consistency.
• Inspection and Quality Control – 3D printed gauges and checking fixtures can be tailored to specific parts, making it easier to verify dimensions and fit.
• Machining Support – Fixtures can be used to hold irregular or complex parts during secondary operations, improving accuracy and reducing setup time.
• Production Line Integration – Lightweight, purpose-built tools can be designed to suit specific workstations, helping streamline workflows and reduce operator fatigue.
• Robotic Grippers and End-of-Arm Tooling – Custom 3D printed grippers can be tailored to specific parts and handling requirements, especially where off-the-shelf options fall short. Using fibre-reinforced FFF technologies such as Markforged, they provide the strength needed for production while remaining lightweight, helping improve robot performance and reduce wear on equipment.

Robotic Grippers and End-of-Arm Tooling

As automation becomes more common in manufacturing, the need for custom end-of-arm tooling is growing. Robotic grippers are often required to handle specific parts, geometries, or materials, and off-the-shelf solutions don’t always provide the right fit.

3D printing offers a practical way to produce custom grippers that are tailored to the application.

Using high-performance FFF systems such as Markforged, grippers can be produced with fibre-reinforced materials that deliver the strength and stiffness required for production environments, while remaining significantly lighter than traditional metal tooling.

This reduction in weight can improve robot efficiency, reduce wear on joints, and in some cases allow for higher operating speeds.

Custom 3D printed grippers also allow for:

• Faster development and deployment of automation solutions
• Easy iteration as part designs or production requirements change
• Integration of complex geometries to better handle delicate or irregular parts

For manufacturers implementing or refining automation, 3D printed robotic grippers provide a flexible and cost-effective way to optimise performance without long lead times or expensive machining.

Choosing the Right Technology

Different 3D printing technologies offer different advantages depending on the application.

• SLS (Selective Laser Sintering) – Ideal for strong, durable parts with good chemical and thermal resistance. Suitable for more demanding production environments.
• MJF (Multi Jet Fusion) – Offers excellent surface finish and consistency, making it well suited to repeatable tooling and end-use applications.
• FFF (Fused Filament Fabrication) – High-performance systems like Markforged are ideal in building larger fixtures or where fibre-reinforced materials are needed for added strength and stiffness.

Material selection is equally important, particularly when considering load, wear, and environmental conditions.

When It Makes Sense (and When It Doesn’t)

3D printed jigs, fixtures and grippers are not a replacement for all traditional tooling, but they are a strong alternative in many cases. They are particularly effective when:

• Production volumes are low to medium
• Designs are still evolving
• Speed is critical
• Customisation is required

For very high-volume, long-term production, traditional tooling may still be more suitable due to durability and economies of scale.

What Next?

If you’re exploring ways to improve your production processes, 3D printed jigs, fixtures and grippers can be a simple place to start.

At Formero, we regularly design and produce these parts to support our own manufacturing workflows, using a range of technologies depending on the application. That same experience can be applied to your projects, whether you need a one-off tool or an ongoing solution.

If you’d like to discuss an idea or see what’s possible, get in touch with the team.

Speak with us today.

3D Printing, Knowledge Hub