In a sector where reliability, precision, and speed are critical, Collins Aerospace – a global leader in aerospace and defense technologies – has taken a bold step forward by integrating industrial 3D printing into its production workflow. Known for its pioneering work in aircraft systems, Collins turned to OMNI3D to solve a persistent tooling issue that was impacting manufacturing quality and efficiency.
The Challenge: Heavy, Inaccurate, and Costly Metal Tooling
To ensure the precision of components in aircraft fuel systems, Collins Aerospace used metal housing jigs for cutting fuel pipes. However, these traditional jigs presented several problems:
- Weight: Each metal jig was heavy and difficult to handle, impacting ergonomics and requiring extra transport aids.
- Deformation: Over time, the jigs bent or warped, compromising dimensional accuracy and part repeatability.
- Cost and Lead Time: Producing new jigs was expensive and slow, especially during global supply chain disruptions.
These issues collectively affected manufacturing speed, quality, and consistency — putting production schedules at risk.
The Solution: Lightweight and Durable 3D Printed Jig
OMNI3D responded by designing and delivering a custom 3D printed jig using the Omni TECH printer. Key features of the new solution included:
- Composite thermoplastic body with metal end caps for enhanced strength and dimensional stability
- Just 2 kg in weight, improving handling and operator safety
- Exceptional accuracy and repeatability, thanks to advanced FFF printing technology
- On-demand production, eliminating long waits for external tooling
The jig could be produced internally, modified quickly, and adapted to future design needs — all while maintaining aerospace-grade precision.
The Results: Cost-Efficiency, Speed, and Manufacturing Agility
The implementation of 3D printed tooling provided immediate and measurable results:
✅ 80% cost reduction compared to traditional metal jigs
✅ Rapid production, even during supply chain disruptions
✅ Higher precision and process repeatability
✅ Improved ergonomics and safety on the production floor
✅ Flexible customization and fast iteration
What started as a tooling fix evolved into a key advantage in Collins Aerospace’s broader push toward more agile and resilient manufacturing.
Ready to Modernize Your Production?
At OMNI3D, we help leading manufacturers like Collins Aerospace unlock new levels of productivity through industrial 3D printing. Whether you’re producing prototypes, tooling, or end-use parts, our solutions are engineered for performance, speed, and savings.
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