Redesign production fixtures for weight, ergonomics, and speed with 3D printing.
Existing production fixtures were designed for machining — solid blocks of aluminum with simple features. 3D printing unlocks fixture designs that are lighter, more ergonomic, and more effective. Our optimization service takes your existing fixtures and redesigns them for additive manufacturing — often reducing weight by 50%+ while improving operator experience and part-holding performance.
Challenges we solve
What fixture optimization teams need from a 3D printing service
Reducing fixture weight without reducing performance
Lattice infill and topology optimization reduce weight by 50%+ while maintaining stiffness on contact surfaces. Lighter fixtures reduce operator fatigue across thousands of cycles per shift.
Improving part-holding reliability
Conformal contact surfaces match part geometry precisely — improving holding force and reducing part movement during operations.
Eliminating loose fixture components
Traditional fixtures often require separate locating pins, clamps, and spacers. We integrate these features directly into the fixture body — nothing to lose, nothing to fumble.
Improving operator ergonomics
Fixtures designed for machining ignore ergonomics — square edges, excessive weight, poor grip. We reshape fixtures for the human hand while preserving all functional requirements.
Technologies
Best technologies for fixture optimization
Materials
Materials for fixture optimization
PC CF for maximum stiffness with minimum weight. Nylon PA12 for wear resistance on part-contact surfaces. PETG for chemical resistance. Material selection is optimized for each fixture application.
PC CF
FDM · Shore D 83
Polycarbonate carbon fiber. High stiffness and heat resistance for demanding structural applications.
Nylon PA12
MJF · Shore D 73
Strong, lightweight, chemical resistant. The standard for functional end-use parts. Excellent fatigue resistance and consistent mechanical properties.
PETG
FDM · Shore D 74
Tough, chemical resistant, food-safe options. Good balance of strength and flexibility.
Common parts
What we build for fixture optimization
Built in our factory
Brooklyn, NY
How it works
Your project, step by step
Send current fixture
Send CAD of your existing fixture (or send the physical fixture for scanning). Include operating conditions and pain points.
Analyze
We identify optimization opportunities — weight reduction, ergonomic improvements, feature integration, and material upgrade.
Redesign
Optimized fixture designed for additive manufacturing. You review and approve before printing.
Print & test
Optimized fixture produced. Deployed on the production floor for operator evaluation.
Refine
Operator feedback incorporated. Final version produced and deployed across the line.
FAQ
Frequently asked questions
Can you optimize fixtures I do not have CAD for?
Yes. Send the physical fixture and we scan and model it before optimizing. The scan-to-CAD process adds 2–3 days.
How do you measure the improvement?
We provide before/after comparisons on weight, part-holding force, assembly time, and ergonomic grip assessment.
How long do optimized fixtures last?
PC CF and Nylon PA12 fixtures handle thousands of production cycles. Wear surfaces can be reinforced or replaced independently.
Other applications
Rapid Prototyping
Functional prototypes in 2–3 business days. Test form, fit, and function before committing to tooling.
Production Parts
Production-grade 3D printed parts at volume — without tooling investment.
Hardware Development
One vendor from first prototype to production parts — no retooling, no requalifying.
Large Format 3D Printing
Single pieces up to 1200mm — or seamless multi-part assemblies at any scale.
Tooling & Fixtures
Custom jigs, fixtures, and assembly aids — delivered in days, not weeks.
Bridge Manufacturing
Ship real product now. Transition to injection molding when you are ready.
Replacement & Spare Parts
Reproduce legacy parts, replace obsolete components, and eliminate spare parts inventory.
Custom Enclosures
Custom enclosures with snap-fits, bosses, and ventilation — production-grade, no tooling.
Low Volume Manufacturing
Manufacture 10 to 5,000 parts without tooling — scale up or down order by order.
Presentation Models & Props
Presentation-quality models, trade show props, and display pieces — finished and delivered on time.
Casting Patterns
3D printed casting patterns — clean burnout, fine detail, no traditional pattern tooling.
Medical & Anatomical Models
Anatomical models, surgical planning aids, and medical training tools — dimensionally accurate.
End-Use Consumer Products
Ship real products to real customers — without injection mold tooling.
Design Verification & Testing
DVT and EVT builds in production-representative materials — validate before you tool.
Product Design Validation
Test form, fit, and function with production-grade materials before committing to tooling.
Investor Samples
Presentation-quality parts that look and feel like the final product — built for boardrooms, pitch decks, and demo days.
Pre-Production Testing
Validate tolerances, material behavior, and assembly flow at low volume before committing to production.
Jigs and Fixtures
Custom tooling for your production line — printed and delivered in days, not weeks.
End-Use Production Parts
Parts that go directly into products your customers buy and use — not prototypes, not samples.
Supply Chain Supplementation
Fill gaps in your supply chain without retooling or waiting months for overseas shipments.
Low-Volume Serial Production
Hundreds to thousands of identical parts — no MOQ from a mold shop, no tooling investment.
Replacement Parts Programs
On-demand spares for legacy and current products — without warehousing inventory.
Architectural Models
Site models, facade studies, and presentation pieces at true scale — printed whole or assembled seamless.
Trade Show Builds
Oversized displays and product replicas built to withstand transport and handling — show-ready finish.
Industrial Housings and Enclosures
Full-size prototypes of panels, covers, and housings — validate before committing to sheet metal or tooling.
Tooling and Molds
Large-format mold masters and lay-up tools — printed faster than machined.
Props and Set Pieces
Camera-ready props for film, TV, and commercial production — on tight timelines.
Wind Tunnel Models
Dimensionally accurate aerodynamic test models at scale — smooth surfaces, tight tolerances.
Legacy Part Replacement
Reverse-engineer and reproduce discontinued parts from scans or drawings — no original tooling needed.
Part Consolidation
Combine multi-part assemblies into single printed components — fewer parts, fewer failure points.
Lightweighting
Topology optimization and lattice structures — cut weight without cutting strength.
Manufacturability Analysis
Evaluate your design for printability before committing to a production run.
Scan-to-CAD
Point cloud in, watertight solid out — production-ready CAD from any 3D scan.
Tooling Design
Custom jigs, fixtures, and mold masters — designed from scratch for additive manufacturing.
Plan Your Project
Tools to plan your build
Check shipping transit times, estimate lead times by technology, and review design guidelines before you upload — so your parts print right the first time.
Check Transit Time
Enter your zip code to see how fast parts arrive from our Brooklyn facility.
Ready to start your fixture optimization project?
Upload your CAD file and get a quote in minutes — or talk to our engineers about your next production run.