Jigs, fixtures, nests and rapid manufacturing
Posted to News on 27th Oct 2009, 10:07

Jigs, fixtures, nests and rapid manufacturing

Jon Severn met Richard Vaughan of First Cut at TCT 2009 and found out how rapid prototyping and manufacturing technologies can benefit machine builders who need jigs, fixtures and nests for automated assembly systems.

Jigs, fixtures, nests and rapid manufacturing

First Cut Prototype's announcements relating to CNC machined plastic parts and aluminium parts in one business day have generated plenty of interest among visitors to MachineBuilding.net and the company is now promoting these services to machine builders and production engineers who need jigs and fixtures, including gripper fingers and nests to retain components on automated assembly cells.

Plastic or aluminium parts will not generally last as long as steel, but they still have an important role to play. In food, drink and pharmaceutical production environments, plastics (of the appropriate grades) are preferred for many applications. For jigs, fixtures and nests, plastics are sometimes specified if there is a risk that delicate components might be marked if brought into contact with metal components. In such circumstances, it might be acceptable for a plastic component to have a finite life, hence it will be designed for ease of manufacture and replacement. Gripper fingers are an example of where this could be the case.

Aluminium might be selected for applications where it is important to minimise weight (perhaps on high-speed machinery), in which case hard anodising might be used to extend the working life of this 'wear part.' But there is another good reason for using aluminium rather than steel, at least initially: speed.

Minimise downtime

If a jig, fixture or nest suffers damage, then it can be expedient to have an aluminium component machined in order to minimise downtime. While this will not last as long as a steel replacement, it will 'buy time' while a steel item is machined and, if necessary, hardened. Furthermore, this steel item can likely be procured at a better price than if a local machine shop is asked to fit an urgent job into an already busy schedule.

When a new jig, fixture or next design is required, aluminium offers another advantage in addition to the potential time saving outlined above. Experience with a new design often leads to modifications being either essential or desirable. If aluminium is used, not only are the existing parts easier to modify but the costs involved in producing a completely new version are lower. This enables the design to be optimised before a commitment is made to expensive, relatively long lead-time steel parts.

If machine builders need plastic or aluminium parts quickly, they can upload a 3D CAD model to the First Cut Prototypes website and the company's proprietary software converts the model into CNC toolpaths, calculates a price and generates a 3D 'as milled' image of the part so that, for example, the customer can see if there are any internal corners that have had to be radiused. This 'First Quote' process is far quicker and easier than the conventional process of sending a drawing or CAD model to a machine shop and waiting for a quote to be returned.

Additional services

Because First Cut Prototype's business is focused on delivering a high standard of customer service, the company also has CAD operators who can, for example, take a CAD model of a component and from that create a model for the necessary jig, fixture, nest or gripper finger, taking into account a customer's written or sketched requirements if necessary. While this level of service enables parts to be turned around extremely quickly, it is much less likely that the machined component can be delivered within the one business day offered for uploaded CAD files.

First Cut publishes a list of plastic materials that it machines, but the company will also work with customers if alternative materials are required, optimising the machining parameters and calculating prices. The standard grade of aluminium offered is 6061-T651 and customers can specify an 'as machined' or a light bead blast finish.

Follow the link to find out more about the First Cut process.

And remember, if you need multiple plastic components then the company's allied Protomold process could be even more cost-effective and just as quick.


Proto Labs Ltd

Halesfield 8
TF7 4QN
UNITED KINGDOM

+44 (0)1952 683047

Bosch Rexroth UK Ltd SICK (UK) LTD Pilz Automation Technology Mechan Controls Ltd ABSSAC Ltd Lenze Selection (a Division of Lenze Ltd) Euchner UK Ltd Murrelektronik Ltd maxon Group HARTING Ltd Heidenhain (GB) Ltd Moore International Ltd Leuze electronic Ltd FATH Components Ltd Smartscan Ltd ifm electronic Limited Aerotech Ltd PI (Physik Instrumente) Ltd Procter Machine Safety Kawasaki Robotics (UK) Ltd STOBER Drives Ltd Rittal Ltd Phoenix Contact UK