Easy 45 Degree Bevel Tool

by RWarren | August 26, 2014 | (7) Posted in Tips

Unlike Josh and the rest of the FliteTest crew most of us do not have a steady hand when cutting with a razor blade.  Especially when it comes to the control surface bevel.  I personally always cut too little or too much but never the right amount. With this problem presenting itself on every foam model I have made I figured there was an easier way. 

 

I wanted to develop a tool that was easy to make and definitely easy to use.  The tool is very simple in its design and is focused around the readily available number 11 hobby knife blade.  The tool consists of the main body that holds the blade in place at the 45 degree angle and the proper 3/16” depth for the perfect cut. A cover piece finishes the assembly capturing the blade for safety.

 

The tool was designed in SolidWorks 3D cad software and can be 3D printed using any FDM (fused deposition modeling) style printer.  I am fortunate to have access to one of the Stratasys printers at work.  I am including the .stl and .step files so that you can print the model as well.  I have also included a foam core board version if you do not have access to a 3D printer.

 

Plastic 3D Printed Version Setup and Instructions:

 

Once the tool has been 3D Printed it may require depending upon your printers tolerances some “work in” to open the blade slot.

 

I would recommend the following steps for inserting the blade:

  • For best results use a new sharp number 11 hobby knife blade.
  • With the blade still in the hobby knife insert the blade with the sharp edge toward the left of the tool(cutting right to left). Note the base of the cutter will have the guide/ guard away from you pointing to the floor.
  • Press firmly until the blade is seated into the vertical guide/guard.
  • Remove the blade from the hobby knife.
  • Slide the cover over top of the end of the blade capturing the blade entirely in the device.  Note the cover should come in contact with the tools main body.

 

To use the 45 degree bevel tool do the following steps: 

  • With the blade mounted and captured in the bevel tool rest the tool firmly against the edge of the foam board at the right end of the edge you wish to bevel.
  • Usually hanging the board over the edge of your work space work best as to keep the cutter path free.
  • Make sure the foam board is full engaged into the corner of the tool guide/guard.
  • With even speed and pressure cut along the edge of the board.
  • Enjoy your straight and evenly cut bevel.

 

 

Foam Core Setup and Instructions:

 

Construction of the foam core version of the tool is as follows:

  • Cut out the foam core profile from the pdf provided.
  • Use the glue sparingly as you do not want any excess of glue on the inside corner of the tool.
  • Use an A fold technique to glue the short leg above the long leg of the tool.
  • Reinforce the outside of the tool with packaging tape.
  • Verify the tool is at a right angle at the inside corner.
  • Insert the hobby knife blade at a 45 degree angle so that it leaves a 3/16” equal spacing from the corner to both points where the blade meets.  Use the sketch location on the drawing for reference.
  • Add a drop of hot glue on the blade’s hobby knife end so that the blade is secured in the tool.

 

To use the 45 degree bevel tool do the following steps:

  • With the blade inserted in the foam core cutter rest the tool firmly against the edge of the foam board at the right end of the edge you wish to bevel.
  • Be careful as to not have the knife blade move in the cutter tool holder.
  • Usually hanging the board over the edge of your work space work best as to keep the cutter path free.
  • Make sure the foam board is full engaged into the corner of the tool guide/guard.
  • With even speed and pressure cut along the edge of the board.

 

I hope you found this article insightful and useful.  Please download and use the design.  I am sure you find this an easy alternative to cutting a bevel free hand.

 

45 Degree Bevel File Set

COMMENTS

udo789 on September 17, 2014
Great idea. I have been looking all over for such a tool. Can I buy one from you?(
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RWarren on September 17, 2014
I appreciate the interest. Unfortunately I am not in a position to print these for anything other than personal use (work place printer not personal). I provided the files so that everyone who has access to a printer can make one. Several companies offer printing services like the one below.

http://www.3dvision.com/stratasys-3d-printing/3d-printing-part-build

There are actually several libraries that offer access to 3D Printers for free. You may want to check with your local library.

http://www.washingtonpost.com/blogs/the-switch/wp/2013/08/01/need-to-use-a-3-d-printer-try-your-local-library/

In addition to libraries several technical colleges and high schools have 3D printers now and offer builds at discounted rates so the students have experience with its use.

Best of Luck

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Duddits4141 on September 23, 2014
Nice work ! was looking for somthing like this also !!!
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kkuenzel on September 26, 2014
Update: I was contacted by 3Dvision by email and they offered to print this for $75 for the base and insert. Much better price but still too high for me.
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RWarren on September 29, 2014
I agree that is high. There are many rapid prototyping companies out there. I have looked and received several quotes regarding different parts and what i can tell you is that the price range varies greatly. Most additive manufacturing firms are used to dealing with big companies so the price is a little higher, however there is a level of expertise and print quality that comes along with the price. You may want to try a couple other firms.
http://www.3daddfab.com
and
http://www.3dprintplanet.org
Both of the above seem to be very reasonable however the print quality may or may not be as good.
Also Hobbyist versions of the larger printers 3DVision and others sell and use are available at reasonable prices.
http://www.makerbot.com

http://web.stratasys.com/US_EM_MojoNewPrice_Sept2014_LP.html?cid=70113000002Evs4

Hope this helps.
Robert
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kkuenzel on September 26, 2014
Wow! just got a quote from 3Dvision and it came to $256 to make one of these out of ABS! Kinda pricey!
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blackkrystal73 on September 17, 2014
I would buy one too.
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mad_milchmann on September 18, 2014
I tip my hat to you! awesome works, Sir!

now i have to find someone with a 3d printer who prints it for me.
or i'll go with the foam version... so many opportunities, thanks to you ;)
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kb0bnz on September 19, 2014
i am unable to find the foam pdf file

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RWarren on September 20, 2014
Download the file set by selecting on the "45 Degree Bevel file Set" link. This will download a .zip file. Extract the file by right mouse buttoning on the .zip file and choose Extract All. Once extracted the 3dcad models and the pdf are in the folder.

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Kevinjt4 on September 17, 2014
Very nice. I made mine out of a block of 1x1 wood and set my table saw to 45 degrees and cut length wise the angle. Now I simply screw in my blades. This also allows me to adjust the depth of the cut so i can make hinges without cutting all the way through.
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Bech on October 14, 2014
Great tool!!! I just printed one out and it took a couple of tries before I got it working properly. Hint: ease up on the downward pressure and the blade will cut the foam like butter. Thanks for sharing your design.
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Easy 45 Degree Bevel Tool