Every drill jig solves the same problem (drill holes in the same place on every part) but the way each type solves it is different. Picking the wrong type adds cost, slows down production, and sometimes makes the part impossible to load. This guide covers the eight drill jig types you will encounter in any precision manufacturing shop, what each one is built for, and how to choose between them for a specific job.
All eight types follow the 3-2-1 locating principle covered in our fixture design guide. What changes is the geometry, the clamping method, and the production volume each design is built to handle.
Quick Comparison Table
| Jig Type | Best For | Production Volume | Cost Range |
|---|---|---|---|
| Template jig | Prototypes, low-volume drilling | 1 to 50 parts | $200 to $600 |
| Plate jig | Flat parts with simple hole patterns | 50 to 1,000 parts | $400 to $1,500 |
| Channel jig | Side-drilling on shafts and round stock | 100 to 5,000 parts | $800 to $2,500 |
| Leaf jig | Medium-volume runs with awkward loading | 500 to 10,000 parts | $1,500 to $4,000 |
| Box jig | Multi-face drilling from one setup | 1,000 to 25,000 parts | $2,500 to $7,000 |
| Indexing jig | Radial hole patterns on cylindrical parts | 1,000 to 50,000 parts | $3,000 to $8,000 |
| Trunnion jig | Drilling on multiple angled faces | 500 to 20,000 parts | $4,000 to $12,000 |
| Universal jig | Multiple part variants in one tool | Mixed | $5,000 to $15,000 |
1. Template Jig
A template jig is the simplest design: a plate with holes drilled where the workpiece holes need to go. The operator places the template directly on top of the workpiece, holds it by hand or with a light clamp, and drills through the template holes.
When to use it
Prototyping, repair work, and one-off jobs. Any time you need to mark or drill a small batch of parts without investing in a hardened production jig.
Limitations
No drill bushings, so the holes wear quickly. The accuracy depends on operator skill. Not suitable for production runs above 30 to 50 parts.
2. Plate Jig
A plate jig is a flat plate with hardened drill bushings pressed into it at the required hole locations. The plate sits on top of the workpiece (held in place by clamps, pins, or its own weight) and the operator drills through each bushing.
When to use it
Drilling hole patterns into flat parts such as brackets, panels, mounting plates, and cover plates. Low to medium production volumes.
Key features
- Hardened steel bushings rated for 10,000 to 100,000 drilling cycles before replacement
- Often includes locating pins that match existing holes in the workpiece
- Light enough to be repositioned by hand
Limitations
Only handles holes drilled from one direction. Not suitable for multi-face drilling.
3. Channel Jig
A channel jig is U-shaped or channel-shaped, designed to wrap around or sit alongside a cylindrical or rectangular workpiece. Drill bushings are mounted on the channel walls so the operator can drill into the side of the part.
When to use it
Cross-drilling shafts, pins, rollers, and round stock. Common in pump, motor, and hydraulics manufacturing where shafts need oil ports or cross-pins.
Key features
- The channel cradles the part and aligns it without needing complex clamps
- V-blocks inside the channel handle round-part locating per the 3-2-1 principle
- Can include adjustable end stops for parts of varying length
4. Leaf Jig
A leaf jig has a hinged top plate (the “leaf”) that swings up like a book cover. The operator loads the workpiece while the leaf is open, then closes the leaf over the part to bring the drill bushings into position.
When to use it
Medium-volume production where part loading is awkward and the operator needs the jig to open wide. Common in automotive and small appliance manufacturing.
Key features
- Hinge mechanism speeds up load and unload by 30 to 50% compared to a fixed plate jig
- Built-in clamping pressure when the leaf is locked down
- Holds higher precision than a template or plate jig because the part is fully constrained
Limitations
The hinge introduces wear over time. Production jigs use replaceable hinge bushings to extend service life.
5. Box Jig (also called tumble jig)
A box jig is a fully enclosed jig with drill bushings on multiple faces of the box. The workpiece sits inside the box, and the operator drills one face, then rotates the entire jig to drill the next face, and so on.
When to use it
Parts that need hole patterns on three, four, five, or all six sides from a single setup. Common in valve manufacturing, pump bodies, gear housings, and engine components.
Key features
- Eliminates re-positioning errors between faces because the part never leaves the jig
- Has machined registration surfaces that the box sits on between drilling operations
- Higher upfront cost but pays back fast in high-volume parts with complex hole patterns
Limitations
Heavy, sometimes 20 to 40 pounds. Often requires a balance counterweight or a fixture stand to rotate safely.
6. Indexing Jig
An indexing jig rotates the workpiece between fixed, locked positions. After each drilling operation, the operator releases the indexing mechanism, rotates the part to the next stop, and locks it before drilling again.
When to use it
Radial hole patterns on cylindrical or disk-shaped parts: brake rotors, gear blanks, flanges, pulley hubs, distributor caps.
Key features
- Pre-machined indexing positions hold to ±0.02 mm angular tolerance or better
- Can be designed for any number of stops (4, 6, 8, 12, 24, etc.)
- Combines well with pneumatic clamping for fast production cycles
Limitations
Only works for parts with regular angular hole spacing. Irregular radial patterns need a CNC, not an indexing jig.
7. Trunnion Jig
A trunnion jig holds the workpiece between two pivot points (the trunnions), allowing the operator to rotate the part to angled positions for drilling holes on inclined faces.
When to use it
Parts with hole patterns on multiple non-parallel faces, especially when the angles are not 90 degrees. Common in aerospace brackets, manifolds, and complex castings.
Key features
- Pivot mechanism with lockable positions at common angles (15°, 30°, 45°, 60°)
- Combines features of a box jig (multi-face) with angular adjustment
- Built heavy for stability during off-axis drilling
Limitations
High setup cost. Best suited for high-value parts where the alternative is multiple separate fixtures.
8. Universal Jig
A universal jig is a modular system with adjustable locators, adjustable drill bushing positions, and interchangeable inserts. It is designed to handle a family of related parts (such as different sizes of the same bracket) without rebuilding the jig for each variant.
When to use it
Production environments running several part numbers from the same family, where building eight separate dedicated jigs is too expensive but accuracy is still critical.
Key features
- Adjustable locating pins on calibrated slides
- Quick-change drill bushing plates
- Documented setup positions for each part number
Limitations
Lower accuracy than a dedicated jig of the same quality level. Best for parts with tolerances in the ±0.05 mm to ±0.1 mm range.
How to Choose the Right Type
Three questions narrow the field down quickly:
- How many parts will run through this jig in its lifetime?
- Under 50: Template or plate jig
- 50 to 5,000: Plate, channel, or leaf jig
- 5,000 to 50,000: Box, indexing, or trunnion jig
- Mixed part families: Universal jig
- How many faces of the part need holes?
- One face: Plate, leaf, or template jig
- Two to four faces: Box jig
- Multiple angled faces: Trunnion jig
- Radial pattern on one face: Indexing jig
- What is the hole position tolerance?
- ±0.2 mm or looser: Template jig works
- ±0.05 to ±0.2 mm: Plate, leaf, channel, or universal jig
- Tighter than ±0.05 mm: Box, indexing, or trunnion jig with hardened bushings
If the answers point to two or three different types, the most expensive type usually wins on total cost of ownership because it eliminates re-setup time and scrap rates.
Yicen’s Approach to Drill Jig Design
Every drill jig Yicen Precision builds starts with three pieces of information from the customer: the part drawing, the expected annual volume, and the available drilling equipment. From there, our engineering team selects the jig type that gives the best cost-per-part across the production run, not just the cheapest tool to build upfront.
Our standard process includes a 3-2-1 locating analysis, drill bushing selection (carbide or hardened steel based on volume), CMM inspection of locating surfaces before release, and a documented load-and-clamp sequence for the operator. For high-volume production, we also recommend bushing replacement intervals so the jig holds tolerance over its full lifecycle.
For a custom drill jig quote or to discuss which type fits your application, contact our jig and fixture engineering team.
Frequently Asked Questions
What is the most common type of drill jig? The plate jig. It is the most cost-effective design for a wide range of hole-drilling jobs and works well for production runs up to a few thousand parts.
What is the difference between a box jig and an indexing jig? A box jig rotates manually between fixed faces (typically 90° between sides). An indexing jig has a calibrated rotary mechanism that locks at multiple programmed angular positions. Box jigs are usually rectangular parts. Indexing jigs are usually round parts.
How long does a drill jig last? Bushings typically last 10,000 to 100,000 drilling cycles depending on material, drill speed, and feed rate. The jig body itself can last decades with proper bushing replacement. High-volume production jigs are designed with replaceable bushings for this reason.
Are drill jigs still used in CNC shops? Yes, in two situations. First, for very high-volume parts where a dedicated drill press with a jig is faster and cheaper than tying up CNC time. Second, for secondary operations after the CNC, such as adding mounting holes or threaded inserts.
Can you 3D print a drill jig? For low-volume or prototype work, yes. The 3D printed body is fitted with hardened steel drill bushings (the printed plastic itself cannot guide a drill bit accurately or wear-resistant). This works for under 100 parts. For production volume, machined aluminum or tool steel is required.
For the complete overview of how these jigs apply across different industries and operations, see our main guide: Drilling Jigs: Types, Applications & Engineering Design.
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