3D-Printed Adjustable Fixtures for Precision Glass Cutting

• Designed and 3D printed modular, adjustable fixtures for precision glass cutting

• Created customizable designs allowing for various tube diameters and cutting angles

• Implemented safety features to prevent glass breakage and operator injury

• Documented designs with technical drawings and usage instructions

Version 1: 45-Degree Fixed Angle Fixture

The initial prototype was designed with a fixed 45-degree angle.

Advantages:

• Consistent 45-degree angle

• Minimal setup time required

• No additional hardware needed

Limitations:

• Lacked a sacrificial back plate, which affected angle consistency

• No mounting plate for the saw table

• Relied on modeling clay for support

• No linear adjustment mechanism

Version 2: Adjustable-Angle Fixture

This version introduced angle adjustability but had several design issues.

Hardware required: 2× M6 Screws, 2× M6 Nuts (for pivot and locking), 1× M8 Screw, 1× M8 Nut (for linear adjustment)

Improvements:

• Adjustable cutting angle

• Added mounting plate for the saw table

• Improved back support design

Limitations:

• Still lacked a sacrificial back plate

• Poor-accuracy linear adjustment mechanism

• Insufficient friction in the locking mechanism

Version 3: Lock Hinge Design

This version significantly improved usability with a quick-locking mechanism.

Hardware required: 4× M6 Screws (for hinge mounting), 1× M6 Hex Head Screw, 1× 12-point flange nut (for linear adjustment), 1× Lock Hinge, ¼" Sacrificial Back Plate, 1× small calibration screw

Improvements:

• Quick angle locking without tools

• Added sacrificial back plate for reusability

• Accurate linear adjustment mechanism

• Calibration screw for 0-degree alignment

Limitations:

• Required external device for angle measurement

• Needed more hardware components

Version 4: Integrated Angle Measurement

Developed simultaneously with Version 3, this design added angle measurement capabilities.

Hardware required: 1× M6 Screw, nut, PTFE washer, O-Ring (for locking), 1× M6 Hex Head Screw, 1× 12-point flange nut (for linear adjustment), ¼" Sacrificial Back Plate

Improvements:

• Built-in angle measurement markings

• Friction-based locking using an O-ring system

• Maintained all advantages of Version 3

Limitations:

• Larger size (potential issue for smaller saws)

• Required specialized hardware

Linear Adjustment Mechanism

A precision feature added in later versions:

• Used M6 screw with 1mm thread pitch for precise control

• One full revolution produced 1mm of linear motion

• Included visual indicator showing 0.25mm increments

• Featured a custom 3D-printed end piece that acted as a contact surface for the glass

Materials and Construction

• All plastic parts 3D printed with PETG at 0.2mm layer height

• Used 4 wall loops and 20% infill (can be increased for durability)

• Parts oriented to minimize supports

• Sacrificial back plate made from polypropylene (PP) to minimize burrs from saw cuts

All the STL files are available upon request.

Example Build