Aerospace Ground Support Equipment Jig
A complex multi-part assembly jig for aligning avionics bay components during maintenance. Replaced a machined aluminium jig at 8% of the original cost and 90% of the lead time.
Overview
A complex multi-part assembly jig for aligning avionics bay components during maintenance. Replaced a machined aluminium jig at 8% of the original cost and 90% of the lead time.
The Challenge
The client's maintenance team was working without a dedicated alignment jig, relying on manual measurement — a slow and error-prone process for a tolerance-critical procedure. The aluminium jig quote came back at over $18,000 with a 10-week lead time.
The Outcome
Delivered a 7-piece PLA-CF assembly jig set in 6 days for $1,450. The parts hold dimensional tolerance within 0.3mm, well within the ±0.5mm requirement. The maintenance procedure time dropped from 4 hours to 45 minutes.
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