Mini ergonomic sanding block

I work a lot with 3D printing post-processing. There are similar designs online that are good but perhaps for a different job like wood finishing. So I designed this tool mainly for processing relatively small and detailed objects. It might work for other jobs but I don’t know, please comment if you use it for other jobs.
 

Highlights and Features

Simple & Clean Design: The entire sandpaper clamping mechanism is integrated directly into the 3D-printed structure. You don't need to purchase or use any additional screws

Standard Sandpaper Scrap Saver: This Mini Ergonomic Sanding Block is specifically engineered around the standard 9" x 11" (23cm x 28cm) sandpaper sheet size (The length of the sandpaper we use is 23mm.) , allowing you to cut your sheets into perfectly usable strips:

• 14mm Wide Strips (Ultra Fine Detail): Specifically designed for the smallest features, tight clearances, and smoothing complex geometries typical of FDM/SLA 3D prints.
• 28mm Wide Strips (Narrow Detail): Excellent for small flat areas, smoothing layer lines, and internal corners on technical parts.
• 42mm Wide Strips (Standard Detail): Offers a wider contact area for stability when sanding slightly larger surfaces or managing initial layer cleanup.

By using these narrow strips, you effectively turn your standard sandpaper sheet into a resource optimized for small, detailed finishing jobs, directly addressing the needs of 3D printing post-processing. 

Note: The width of the tool is intentionally reduced by 1mm specifically at 13mm, 27mm and 41mm. This allows us to have a margin of error in cutting the sandpaper while also avoiding the edge of the tool being scraped against the object instead of the sandpaper.


Specialized Detail Sanding Tips: To perfectly handle fillets, curves, and tight corners, the tool integrates two precisely calculated radius tips:

• Sharp Tip (R1mm / 1mm Radius): The extremely tight radius is ideal for sanding deep grooves, sharp internal corners, or high-detail 3D print features.
• Large Tip (R2mm / 2mm Radius): The 2mm radius tip smooths out wider curved corners easily and uniformly, achieving a professional finish

Ergonomic and Comfortable Grip: The body of the tool features a convenient recessed hand groove for a comfortable fit. This ensures better control over the sanding force and position, reducing hand fatigue during extended use.
 

Printing Details

• Material: PLA, PETG (PETG or ABS/ASA are highly recommended for better durability and heat resistance, especially during high-speed sanding).
• Axis: print with the direction already set in the files
• Layer height: Normally only need to print with 0.2mm layer but if print with lower layer height the screw will be smoother
• Walls: Recommended more 4 wall in screws and other parts at least 2 layers of wall
• Supports : No support required
• Fuzzy skin: Not required but recommended to have increased grip when holding. Create fuzzy skin on the grip grooves on both sides (In the 3mf files I have already drawn the fuzzy skin area)