Abstract
Fixtures are production tools that are used to accurately locate and clamp automotive BIW (Body in White) components together, with respect to the vehicle origin for assembly. In automotive product development, prototype bodies are built on a compressed fixture line with the intent of validating the product design. Reconfigurable modular fixtures are used for limited quantity BIW production. The prototype weld fixtures are typically manufactured with mild steel or cast iron. The use of metal fixtures results in a heavy apparatus with a long development lead time, and an inherent shape limitation arising from conventional manufacturing processes. This paper explains the construction and use of 3D printed portable hand fixtures developed using FDM technology, to assist in Proto BIW development. The shorter lead time, lower weight and ease in development of complex shapes are leveraged to overcome the limitations of conventional manufacturing processes. The use of functional features, rather than the datum features of the smaller sheet metal BIW components, reduces the effect of manufacturing variations on the final geometry of the BIW assembly. The light weight of the weld fixtures reduces fatigue of operation, and the portability results in an effective use of facility floor space.