Case Study: Jigs for Automotive Metal Fabrication – Jigs & Fixtures – RoFo Automotive

Introduction

Problem Statement

RoFo Automotive – Innovating vehicle manufacturing with cutting-edge automation and smart solutions.

When RoFo Automotive needed high-precision jigs to streamline metal fabrication for five different car brands, traditional methods fell short. Conventional metal fabrication:

• Lacked precision, leading to alignment and fitment issues.
• Had long lead times, delaying production efficiency.
• Was not scalable, making it difficult to replicate designs quickly.

3DX Solution

Using 3D scanning, advanced CAD modeling, and Multi Jet Fusion (MJF) technology, 3DX designed and manufactured 24 unique stencil jigs with unmatched precision, enabling RoFo to accelerate fabrication while ensuring top-tier quality.

Process

1. Reverse Engineering & Digital Scanning

The first step was capturing the exact measurements of different car areas:
• Shining 3D Freescan Combo+ was used to 3D scan multiple cars at the client’s site.
• Geomagic Design X allowed us to reverse engineer precise CAD reference parts.
• The data was optimized to develop jigs that perfectly fit each car model.

2. Designing Custom Jigs & Fixtures

Using the scanned data, 24 different stencil designs were created across five car brands:
• Geomagic Design X enabled precise shape modeling, maintaining tight tolerances.
• Fusion 360 was used to optimize the stencil designs for accuracy and usability.
• Each jig was tailored for seamless integration into RoFo’s fabrication process.

3. Protoyping and Testing

• The first set of jigs was printed in PA 12 material using MJF technology.
• Accuracy and durability were validated through real-world testing.
• Any necessary refinements were made before full-scale production.

4. Full Scale Production

With successful prototyping, we moved into full production:
• 48 jigs (two sets of 24) were manufactured in just three days.
• MJF technology’s support-free design allowed maximum design flexibility.
• Final jigs were sandblasted and delivered for immediate use.

5. Deployment & Future Scalability

• The jigs were installed and tested for seamless functionality.
• RoFo Automotive can now use these jigs for future fabrication projects, ensuring consistency and speed.
• The solution significantly reduced production time and improved quality.

6. Digital Inventory Just-In-Time Manufacturing

The stencil jigs are now digitally stored, categorized by car brand and stencil type.
This means:
• On-demand reprints can be produced instantly when needed.
• Elimination of physical storage constraints, reducing costs.
• Future scalability for additional car brands and modifications.

Results

With 3DX’s advanced additive manufacturing, RoFo Automotive achieved:

• Faster fabrication times with precise, scalable jigs.
• Higher accuracy and fitment, reducing errors and rework.
• A sustainable, digitized inventory system, enabling Just-In-Time (JIT) production.

RoFo can now efficiently manufacture metal components with unparalleled precision, all while ensuring long-term cost savings and operational efficiency.