Subaru Indiana Replaces ABS Jigs With Markforged Onyx GF

Color-Coded Tooling for Bumper Labels

Subaru of Indiana Automotive is using Markforged Onyx GF to produce color-coded jigs that position QR labels on bumpers as they move through the paint shop. The labels are applied before painting and read by fixed overhead scanners. Because bumpers do not have built-in locating features, operators previously placed labels by hand, leading to inconsistent positioning and missed scanner reads.

The new jigs reference the external geometry of each bumper and hold the label to a tolerance of 0.1 mm. Separate tools were produced for different vehicle models, front and rear bumpers, and trim levels. Each variant gets a different color, so operators can pick the right jig at a glance.

A Second Life for an Assembly Jig

On the assembly side, SIA needed a base cradle jig for cam cap carriers. An earlier version made from ABS cracked under repeated use. The team replaced it with a yellow Onyx GF part printed on a Markforged system. The new tool resists the cracking the ABS version suffered, and the color signals where the tool belongs on the floor.

The two cases show how SIA is combining material properties with visual coding. The bumper jig controls label position while color separates vehicle variants. The assembly jig gains durability while its color communicates purpose.

3D Printed Tooling Is Already Familiar at Subaru

SIA is not starting from scratch. Earlier in 2026, Subaru of America reported using a Stratasys F770 to produce accessory-installation tooling in-house, cutting development times by more than 50% and fabrication costs by roughly 70%. Nissan's Barcelona plant has produced more than 700 parts using BCN3D FFF systems since 2021, reducing some tooling lead times from one week to one day and lowering costs by up to 95%.

The move to Onyx GF at SIA reflects a step beyond basic thermoplastics. The material adds stiffness and strength while keeping the ability to print complex geometries in a range of colors. For a multi-model line where tooling changes with every variant, that flexibility matters.