Production Fixtures & Batch Jigs

A great jig turns a 5-minute job into a 30-second job. Repeatable position = repeatable settings = consistent results. The CO2 production shop's secret weapon.

The production-jig mindset

Manual loading takes 45 seconds. Manual focusing takes 30 seconds. Manual framing takes 60 seconds. Total per part overhead: ~2.5 minutes. On a 50-piece run, that's 2 hours of pure loading time.

A jig that drops the part to a known position eliminates focus + framing for repeat jobs. Per-part overhead drops to 5-10 seconds. 50-piece run gains 100 minutes back.

Build a CO2 jig: the right way

1. Decide the part datum, the corner or edge that defines position. Usually a corner.
2. Measure the part precisely with calipers.
3. Engrave (or laser-cut from a CO2) a position template on a sheet of MDF / aluminum / acrylic that matches your bed. Add hard stops at the datum corners.
4. Add registration markings, visible reference for Z height + alignment.
5. Number / date / version the jig. Store with the job folder.
6. Mark the Z height on the jig so you can re-set focus instantly when loading the jig.

Common CO2 production jigs

Multi-up coaster jig

4×4" wood blank coasters; 6 pockets in a sheet of MDF. Jig holds 6 coasters at a known position; one Lightburn file engraves all 6 with rotated/varied designs.

• Sheet of 18" × 12" MDF, pockets cut at 4×4" with 1mm clearance per side.
• 1mm magnets at each pocket corner (for ferromagnetic substrate).
• Datum corner at front-left for consistent loading.

Tumbler / drinkware jig (with rotary)

Custom V-block + rotary coupler. Tumbler drops onto V-block which is referenced to the rotary's Z coordinate.

• Match V-block height to the tumbler diameter family (20oz / 30oz / 40oz).
• Use removable shims for cross-family compatibility.
• One jig per common tumbler size = one Z calibration per family.

Knife handle / blade jig

Magnetic V-block with adjustable angle for tapered knife blanks. Blade rests on the V; magnet holds the spine.

Flat plate jig (multiplaque)

Brass / aluminum plates 60×80mm; 8-up arrangement on a magnetic base. Each pocket has a unique CSV-driven name + serial number engraved via Variable Text.

Notebook / journal cover jig

For leather journal covers, adjustable corner stops accommodate different sizes (A5, B6, etc.). Foam padding under the cover prevents the laser from scoring through to the bed.

Wedding favor box jig

Pre-made paper boxes (50-200 batch) drop into pockets; small magnets hold them open during engrave.

Multi-up Lightburn array

Lightburn duplicates one design across an array, perfect for jig-matched layouts:

1. Design the single piece (e.g., one coaster).
2. Select; Edit → Array (or Tools → Array).
3. Set rows, columns, X/Y spacing to match your jig.
4. Lightburn creates the multi-up file.
5. Run as one job. Galvo doesn't care; gantry runs all faster than individual jobs.

Variable text for serialized work

For jobs where each piece has a unique name / number:

1. Build the design with a placeholder text element.
2. Lightburn → Window → Variable Text. Set source to a CSV.
3. CSV first column populates the placeholder.
4. Each "Run" pulls the next row.
5. Pair with a foot pedal for hands-free production.

Foot pedal workflow

For high-volume production:

1. Connect foot pedal to laser's accessory port.
2. Load part.
3. Tap pedal, Lightburn runs the active job.
4. Unload completed part.
5. Repeat.

Removes the hand reaching for the keyboard; throughput rises ~30% on repeat work.

Material-saving fixturing

• Drop-down sheet handling: for cuts on full sheets, set Lightburn's "Cut after" delay so multiple jobs can run on one sheet without re-loading.
• Honeycomb riser blocks: for production with multiple parts at different focal heights.
• Vacuum table: premium upgrade. Holds parts flat; eliminates warping. Worth it for production fabric / paper / thin material work.

Jig storage & versioning

• Number every jig (J001, J002, etc.).
• Store with the corresponding Lightburn project file.
• Tag jig with: customer name, part name, Z height, last-used date.
• Replace MDF jigs every ~50 production runs (the laser cuts also wear the jig surface).