Specialist Tooling for Engine Builders Using Markforged Onyx
Specialist precision Tooling for Engine Builders Using Markforged's Onyx
Engine builders require a lot of expensive specialist tooling. These are often used for one process on one series of engine and are not only expensive but sometimes simply not available to the public. We initialy started design of our line of engine building tools to use in our workshop however their great success has prompted us to start our line of engine building specialist tools.
These needed to be:
- Lightweight and easy to handle
- Simple and accurate to limit user error
- Durable enough for years of workshop use
- Cost-effective and rapidly produced
Of course they also had to look great and be a pleasure to use!
We saw a perfect opportunity to apply our years of engine building experience, our CAD abilities and our 3D printing capabilities.
We designed and produced a range of custom tools including:
- Piston ring compressors, sized to fit a variety of piston diameters, simplifying the installation of pistons into bores while ensuring no damage to the rings
- Crankshaft run-out gauges with stable bases and integral alignment features
- Piston ring depth tools set piston rings in the specific location of the bore to accurately check ring end gap.
- Deck height/TDC measuring tools used to measure the height of the piston relevant to the gasket service of the cylinder and can also be used to find true TDC when measuring cam timing.
- Custom alignment and holding jigs, tailored to the specific geometry of individual engine blocks and components
Each tool was printed on our Markforged industrial printers, delivering high dimensional accuracy, excellent surface finish, and professional durability. The tools themselves are printed in Onyx, a trademark material of Markforged. Onyx is a micro carbon fiber filled nylon that yields accurate parts with near flawless surface finish. Few materials have the versatility of Onyx; it offers high strength, toughness, and chemical resistance when printed alone, and can be reinforced with Continuous Fibers to yield aluminum-strength parts ensuring no flex or movement when measuring critical tolerances. Onyx is flame-retardant, dimensionally stable, and resistant to oils and workshop chemicals—making it ideal for repeated workshop use.
To complement the tools, we also designed and printed in lightweight PLA perfect-fit tool trays for each item. These trays provide safe, space-efficient storage in workshop toolboxes and make it easy for technicians to identify misplaced tools at a glance, improving both organisation and accountability in high-pressure environments. The trays are able to lock into a grid plate that is installed into toolbox drawers to ensure everything remains neat and secure. Tool trays are all laser etched with relevant specifications and Elliott Motorcycles logo.
Our tools offer all the benefits of the OEM tools and even fill the gaps where tooling is unavailable. They have already performed flawlessly across multiple engine inspections and rebuilds, holding up to workshop demands while making handling easier and more efficient.
More importantly, our ability to 3D print new tooling within days meant we have been able to create custom-fit tools for customers with unique requirements without delay—cutting downtime and increasing productivity.
These examples illustrate how Elliott Motorcycles bring advanced engineering materials and on-demand digital fabrication together to support professionals in all sectors of engineering.
From specialty engine jigs to precision-fit trays and measuring tools, we’re delivering smart, scalable workshop solutions built for the real world—without compromise on quality or strength.
