Hybrid Welding Jigs with Additive Manufactured Functional Elements

This paper deals with the development and design of hybrid welding jigs with additive manufactured (AM) functional elements for pre-series automotive body shops. The designing of the hybrid welding jigs is based on a modular toolkit consisting of standard elements, additive manufactured elements and conventionally manufactured elements, such as 2D cut steel beams and machined location pins. In order to select the most suitable AM material, the AM materials with the highest cost-specific stiffness are analysed. The selected materials are then evaluated by a three-point bending flexural test for validation of the welding jig requirements. Finally, an example hybrid welding jig is designed and tested.