3D Printing Custom Metal Tool Pieces
Designed for the job. Prototyped fast. Manufactured in metal.
The Challenge
The team at Mick Tighe 4x4 had a workshop tooling problem.
While working on Next-Gen Ford Rangers, the technicians needed specialised tooling for two specific applications: a tool head suited to the Next-Gen Ranger wheel nuts and another designed for Ironman suspension and strut installation.
The problem was simple. There wasn't a suitable off-the-shelf tool available for either job.
Rather than continuing with makeshift solutions or modifying existing tools, we saw an opportunity to create purpose-built tooling specifically for the components our technicians were working with.
Instead of asking, "What tool can we buy?", the question became:
"What tool do we actually need?"
That's where Forma 3D stepped in.
Designing the Solution
The first step was understanding exactly how each tool needed to interact with the vehicle components.
Rather than designing a generic socket or tool head, we developed the geometry specifically around each application, taking into account critical dimensions, clearances and engagement surfaces.
From there, the specialised tool heads were drawn in CAD.
Starting from scratch meant we could design around the job itself rather than being limited by existing tooling. It also allowed us to manufacture exactly what was required without dedicated moulds, dies or large production quantities.
Once the CAD designs were finalised, we were ready to validate them before moving into metal production.
Prototype Before Production
Although the finished tools needed to withstand the demands of everyday workshop use, producing them immediately in metal didn't make sense.
We first printed prototypes in PLA.
This gave us a fast and cost-effective way to physically test both designs on a real Next-Gen Ford Ranger before committing to the final material.
For the wheel nut tool, we could check that the specialised socket geometry engaged correctly and provided the required access around the wheel nut.
For the Ironman suspension tool, we tested how the design interacted with the strut and suspension assembly and whether it was practical for technicians to use during installation and servicing.
The process was straightforward:
Design → PLA Prototype → Test on Vehicle → Refine → Metal Production
By validating the geometry first, any changes could be made in CAD before producing the final metal components.
Moving Into Metal 3D Printing
With the prototypes tested and the geometry confirmed, we moved into final production using our Markforged Metal X system.
The tools were manufactured in 17-4 PH stainless steel, selected because these weren't display pieces or prototypes. They needed to become functional workshop tools.
17-4 PH stainless steel provides the strength, hardness, durability and corrosion resistance required for demanding mechanical applications.
The Metal X was particularly well suited to the project because we only needed small quantities of highly specialised tooling.
Rather than investing in traditional production tooling, the validated CAD files could move directly into metal additive manufacturing.
The Final Product
The result was two purpose-built stainless steel workshop tools designed specifically around Next-Gen Ford Ranger applications.
One was developed for the Ranger wheel nuts, while the other was designed specifically for the Ironman suspension and strut assemblies fitted to the vehicle.
Because both designs had already been tested as PLA prototypes, we could move into metal production knowing the fundamental fit and functionality had already been validated.
The finished tools are now being used by technicians in the Mick Tighe 4x4 workshop as part of normal servicing and suspension installation work.
Rather than adapting the job to suit the tools that were commercially available, we designed the tools around the job.
Need Custom Tooling for a Specific Application?
Forma 3D can help take specialised tooling from an initial requirement through to a functional finished product.
Using CAD design, rapid prototyping and metal additive manufacturing, we can develop low-volume custom tools, fixtures and components around the application they're actually needed for.
Get in contact with our friendly team today.
Location: 11 Mort Street, Toowoomba, QLD
Email: admin@forma3d.com.au
Phone: (07) 4588 6659