3d Printed Hybrid Welding Jig for Aluminium Curved Tube Frame Assembly

The Challenge

We were tasked with producing a complex curved prototype welded structure from 6061 T6 aluminium tube. This required production of a low cost welding jig that could enable accurate positioning of curve formed tubes as an assembly in readiness for final TIG welding.

“3d printing changes the way we can approach and solve manufacturing challenges. It opens up new ways of reducing costs, time to manufacture, whilst increasing accuracy ”

Our Solution

The curved tube assembly and jig design was developed in CAD. 3d printable jig struts were designed with key mating surfaces driven off the final welded tube structure design. The struts were positioned on an aluminium jig plate, far enough away from the weld sites to avoid being affected by the weld heat. 3d printing these jig struts enabled a fast alternative solution to CNC machined struts.

CAD design driven from the Aluminium 6061T6 tube assembly surfaces.

Struts were then printed on our Markforged 3d printer. Onyx with HT glass fibre material was used to print accurate heat resistant jig struts to an accuracy of 0.1mm and with good dimensional stability. Nylon is capable of withstanding ****** during use.

Strut fixing holes were positioned from the CAD and CNC machined into a reusable aluminium plate. The resulting jig assembly enabled precise, repeatable and fast positioning of assemblies.

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