Subaru of Indiana Automotive Adopts Color-Coded Markforged Tooling

Subaru of Indiana Automotive (SIA) has replaced ABS assembly jigs with Markforged Onyx GF 3D-printed tooling on its multi-model production line. The change lets operators instantly identify which jig belongs to which bumper variant by color, cutting down the confusion that builds when three vehicle models run at the same time.

The old ABS tools cracked after repeated handling. Rob Cooper of SIA said the visual distinction matters most when line speed is high and operators have only a moment to grab the right fixture. Onyx GF delivers the durability needed for daily reuse while allowing each model variant its own color.

One specific job involves positioning QR labels on bumpers before they enter the paint shop. The jigs reference the external geometry of each bumper and place labels to a 0.1 mm tolerance. Missed scans used to halt the line while staff manually reconciled parts. The color-coded jigs reduce those misses by making tool selection obvious.

SIA also uses Onyx GF for cam cap carrier cradles, where the previous ABS base cracked during handling. The new jigs hold the same geometry but survive the assembly environment longer.

The plant already had Markforged machines on site, so the switch to Onyx GF required no new hardware investment. Different colors map to different vehicle variants and factory locations, turning every tool into a self-labeling fixture.