Templates, Jigs, Formers & Moulds

Templates, jigs, formers and moulds are tools used to improve consistency, speed, and accuracy when making prototypes or batches of parts

They reduce reliance on skilled manual work and ensure repeatable results with minimal errors

Common in wood, metal, plastic and composite manufacturing processes

Templates are flat patterns or guides used to mark out shapes onto materials

Often made from card, MDF, acrylic or sheet metal

Ideal for repeated, consistent layouts or outlines

Templates – Evaluation:

Advantages	Disadvantages
Speeds up marking out and layout Ensures consistency in repeated parts Easy to store and reuse Can be made from low-cost materials	Only guides marking – doesn't assist actual cutting or shaping Can wear down or become inaccurate over time Doesn't prevent human error if poorly aligned

Common Uses:

• Marking outlines of fabric pieces
• Tracing product shapes onto wood or foamboard
• Cutting consistent window panels or panel inserts

Jigs are tools that hold or guide a workpiece and a tool to ensure precision during cutting, drilling, shaping or assembling

They reduce human error by physically controlling position or movement

Often custom-made for specific repetitive tasks

Jigs – Evaluation:

Advantages	Disadvantages
Ensures accurate and repeatable operations Increases safety by stabilizing parts Reduces reliance on operator skill Speeds up repetitive tasks	Can be time-consuming to design/build Only useful for specific tasks or parts Can wear down or lose accuracy

Common Uses:

• Drilling holes in precise locations
• Holding joints square during assembly
• Guiding a router for complex cuts

Formers are shapes or moulds used to bend, shape or press materials into specific forms

Used with heat (e.g., plastics) or pressure (e.g., laminated wood)

Allows creation of consistent 3D shapes

Formers – Evaluation:

Advantages	Disadvantages
Ideal for producing identical curved or shaped parts Reusable in batch or mass production Can be simple or complex depending on need	Only works with materials that can be formed or bent Inaccurate formers can ruin outcomes May need careful clamping or heating

Common Uses:

• Bending acrylic sheets with a line bender
• Laminating plywood for chairs or skateboards
• Forming vacuum-formed plastic shapes

Moulds are hollow containers or shapes used to cast or form materials such as resin, plastic or metal

The material takes the internal shape of the mould and sets or cures

Used in casting, thermoforming and composite lay-up

Moulds – Evaluation:

Advantages	Disadvantages
Can produce highly detailed, accurate shapes Allows for batch or mass production Supports complex internal and external forms	Initial mould production can be expensive Mould release agents may be needed Trapped air bubbles can affect quality

Common Uses:

• Resin casting for prototypes or jewellery
• GRP moulds for automotive panels
• Vacuum forming plastic packaging

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