3d printing of a drill jig for accurate drilling of aluminium tube

The Challenge

To design and manufacture a cost effective drill jig that will enable accurate, repeatable hole drilling through the centre line of a 30.8mm diameter aluminium tube.

The Solution

We designed and printed a split tool with press fit hardened steel drill bushes. Markforged ONYX nylon was used as the print material, creating a strong, tough, temperature resistant jig body. A 0.1mm print accuracy enabled press fit tolerance for the steel drill bushes and accurate bush positioning. Drill detail numbering featured were designed into the tool surface for ease of identification. The jig allowed 'soft jaw' type clamping onto the aluminium surface, avoiding tube surface damage with high clamping forces.

Rendered image of the assembled jig tool design with numeric identification marks in the surface

Exploded rendered image of the jig tool components

Rendered animation of the jig tool in operation

3d printed jig tool with press fit hardening tool steel bushes and jig pin. 0.2mm layer print resolution. Material: Onyx fibre reinforced nylon engineering thermoplastic.