UltraJig - Parametric xTool F2 Ultra Modular Sliding Fence and Jig System

Motivation

The F2 Ultra class of xTool machines has a grid for attaching any number of jigs. From what I have seen, the default approach to designing most jigs is to rigidly bridge the workpiece contact points to the closest grid attachment point. That works, but has some shortcomings:

• Every jig is unique to only that specific setup requiring a lot of printing, the need to store the large jigs, and potential waste.

• Rigid jigs require more fine tuning to get perfect and reduce the setup flexibility when a workpiece deviates from the designed ideal.

Solution

Design and print a fence and jig system to accomplish the following objectives:

• Transform one 3D mounting challenge into three 1D solutions oriented in each axis

  • X axis – Fence with jig grid and work area indices

  • Y axis – Dual sliding and lockable fences with work area indices

  • Z axis – Custom accessories which can be designed and positioned anywhere in the work area (XY plane) providing support, fence stops, differential rise, batch jig alignment, etc.

• Fully parametric providing customization of all dimensions, automatic relabeling based on parameter changes, and adaptability for a wide range of custom accessories

• Enclosure able to close completely

• Zero interference with the working area and minimal interference with the area outside of the working area

• Compatibility with Mag-align - The fence is at the same height and I have designed horizontal spacers which use the same jig grid.

• Labels to make finding the right accessory easier

• Standardized hardware using tools already provided by xTool (i.e., M4 and M3 socket)

• Minimal supports

• Looks good

Design

• Work area – To minimize interference, I placed the slides as far as possible away from the center along the Y axis while avoiding interference with the enclosure along the front edge

• Slides – I chose 3/8” hardwood dowels for the slides. The dowels I purchased measured ~9.70 mm, but after sanding they were ~9.50 mm. That is the dimension I used for the mounts and shuttles.

• Jig grid

  • Spacing (X and Y axis) – 5.0 mm

  • Slot dimensions

    • X and Y – 2.5 mm

    • Z depth – 8.0 mm

• Fence

  • Width is 10.0 mm wide for a few reasons:

    • The attachment points accept M3 heat set inserts by default, and I wanted plenty of plastic for those to grip

    • Two jig grid rows so each station along the Y axis can perform at least two functions (e.g., rise and stop, etc.)

    • Fence can be installed in either of two orientations keeping the front and back sides flat on both sides

  • Connection points use M3 heat set inserts by default so the fence(s) can be easily removed/reinstalled consistently without causing damage or for additional optionality with alternative fence designs. If you would like to more permanently screw directly into the fence plastic, reference the customization section.

  • To minimize friction and elephant’s foot, there is a 0.50 mm vertical and horizontal clearance as well as a 1.0 mm chamfer along the bottom face. This means that workpieces shorter than ~0.50 mm will not properly contact the fence face(s). If you want less clearance, reference the customization section.

   Updates and Enhancements

      v1.1

• Accessories - Implemented a standard template, parameter, and label scheme completing the set needed for basic UltraJig functionality along all three planes and axes.

  

  

  • The UltraJig accessory design approach also makes them extensible for use in other designs.

    • Parametric Galvo Laser Centering Guide

    • Mag-align Extenders

  • Types - There are multiple types of accessories with different purposes. Some are meant to position and center workpieces along a plane, others guide along a single axis, and some help extend that functionality. They are all meant to work together and many can nest within other accessories.

    • Risers - Position, center, and raise workpiece along the XZ plane. All Risers start with a BaseHeight of 5.0 mm.

      • Flat - Complete set of models provided

        • Risers ≥ ~8.5 mm can be nested with other Flat risers and accessories so that a complete set of flat Risers and Spacers allows for any Z axis adjustments necessary. Since all Risers start with a BaseHeight of 5.0 mm, a Flat 5.0 mm on the other end of the workpiece can serve as a level reference.

        • Can also be used behind other risers to prevent workpieces from sliding along the Y axis.

      • Circular - Only a 50.0 mm diameter model is provided. Use the Fusion file to create any other size.

      • Polygonal - Models are provided for an equilateral triangle (3), square (4), pentagon (5), hexagon (6), octagon (8), and decagon (10). Use the Fusion file to create any other polygon or custom angle.

    • Shifters - Position, center, and shift the workpiece along the XY plane

      • Circular - Only a 50.0 mm diameter model is provided. Use the Fusion file to create any other size.

      • Polygonal - Models are provided for an equilateral triangle (3), square (4), pentagon (5), hexagon (6), octagon (8), and decagon (10). Use the Fusion file to create any other polygon or custom angle.

    • Spacers - Stack to make small adjustments in the Z axis to Risers and Shifters not possible with Flat Risers.

    • Pylons - Place alongside your workpiece to use as a Y axis positioning reference. Rotate around the Z axis for small incremental adjustments.

    • Customization - Pay attention to the Parameter notes in Fusion when customizing

    • Labels - As in v1.0, the Fusion files have a shallow cut extrusion feature at the end of the timeline. I included models with and without these debossed labels. If you have the F2 Ultra UV and prefer to mark the prints, I also provided the labels in an .xcs file with each Riser and Shifter type on a separate canvas here on Atomm.

• Fences - Many users do not have set inserts. Now you can either install a nut during assembly or embed one during printing. The model, Fusion, and PrusaSlicer project files are all updated with these two new versions:

  • New! Bottom nut slot

    

  • New! Embedded nut slot. Pauses are already inserted on the bed containing these models in the PrusaSlicer project file.

    

      Planned

• Snap on divider fences for batch grid processing

• RA2/3 support (the right slide which seems like an obstruction can be turned into an solution…think pivot point)

• Support for metal rod (~9.70 mm) slides

Customization

The Fusion files are included. You can customize the parameters (DESIGN | SOLID | MODIFY | Change Parameters) as necessary. When you open the Parameters dialog, first sort by name. The parameters most optimized for customization are favorited and commented in detail to help you. The non-favorited parameters should work as well but may require more tinkering to repair broken downstream features.

I anticipate most people will print and use the sliding fence system parts as originally designed. For those who would like to make changes to it, you can reference the .f3z file which contains linked subassemblies. Please let me know if Fusion gives you any problems with editing individual components. If you think your changes will benefit everyone, please contact me before sharing a derivative of the entire system only for minor changes for things like fitment, etc.. I would prefer to keep the main system design in one place.

If you cannot get Fusion to work for you, please send me a message (see below) and I will post your requested model files at my earliest convenience.

Materials

• Screws

  • (4) M4x8 machine w/ countersunk head (M4x10 should also work)

  • (12) M3x10 machine w/ round head

    • Four will be used to tighten the dowel to the mounts. 10 mm is the minimum length for those.

    • Four will be used routinely for locking and unlocking the shuttles. Because of this, you may find it easier to use 12 mm as the minimum length instead.

    • Four will be used to connect the fences to the shuttles. Screws lengths in the 8 to 12 mm range should work.

• Nuts

  • (8) M3 hex

• (recommended) Washers

  • (12) M3

• Heat Set Inserts

  • (4) M3

• Slides

  • (2) 3/8” x 261.0 mm (~10 5/16”) dowels. I used hardwood dowels from Home Depot. Check that they are as straight as possible.

  • Alternatively, Home Depot also sells 3/8” metal rods. I chose to stick with wood to keep prototyping easier but may try the aluminum rods as an upgrade if it will make the slides work a little smoother. That rod measures the same 9.70 mm so the default mounts and shuttles will not work…standby.

Printing

See the attached .3mf for my settings and model orientation. I printed with TINMORRY Metallic PETG Rose Gold.

   Parts

      Required

• PrusaSlicer Project Bed 1

  • (1) MountBack (Left)

  • (1) MountBack Mirrored (Right)

  • (1) MountFront (Left)

  • (1) MountFront Mirrored (Right)

  • (1) ShuttleBack (Left)

  • (1) ShuttleBack Mirrored (Right)

  • (1) ShuttleFront (Left)

  • (1) ShuttleFront Mirrored (Right)

  • (2) Fence

      Optional

• PrusaSlicer Project Bed 2 - F2 Ultra marking and cutting alignment jigs

  • (2) DowelJigs

  • (2) FenceJigs

I designed and prototyped on a Prusa CORE One.

Let me know (Messenger | Printables.com) if you have any questions.

Post-Processing

   Dowels

1. Cut the (2) dowels to 261.0 mm (~10 5/16”) OR wait and use the cutlines when adding the indices in the laser.

2. (recommended) Sand the dowel down to as smooth as possible using increasing grits (I stopped at 400) and a diameter of ~9.50 mm.

   Printed Parts

1. Cleanup any stray filament and deburr the edges of the fences to ensure a perfectly flat front and back edge

2. Insert a nut in each of the (8) recesses. Needle nose pliers or a similar tool can help.

3. For each of the (8) locations from step 2, insert and tighten the screw all the way pulling the nut all the way into the recess. Then loosen each screw until the thread releases and then screw back into the nut for a half turn. This will also give you an idea of how much travel the M3x10 screw provides. Reference the Materials section for optionally longer screws for some of the parts.

   

4. Install the heat set inserts ensuring any excess plastic that squeezes out is pressed back down or sanded flush

   

5. Check the fence(s) to ensure they are not bowed. If they are, careful use of a heat gun can help to correct it.

6. For the M4 countersunk screw holes, consider threading them by driving a screw through each before mounting.

   (recommended) Indices

The xTool Studio (.xcs) files containing the graphics and my settings are on Atomm.

      Markings and Cut Lines

I provided the files (.dxf and .ai) for the graphics and settings I used to mark the dowels and fences. Cutlines are also included for the dowels. In each of the Illustrator files, there are saved Selections you can use for exporting.

      Production Jigs

I cut and marked my dowels in the P2 using a few simple jigs (provided) cut out of 3 mm birch plywood. I marked my fences in the F2 Ultra UV using a couple of jigs (provided) mounted to the jig grid with two of the M4 screws.

Installation

1. Screw the (4) mounts to the four corners of the baseplate. Tighten all the way down then loosen one full turn.

   

2. Insert the dowels so that their beck ends extend a few cm past the backside of the front mounts

3. Slide the respective front then back shuttles onto the dowels

4. Insert the back ends into their back mounts aligning the front edge of the back mount with the double-arrows (if no indices, slide the dowels until they touch the back face of the back mount). Tighten the M3 screws on the back mounts only.

   

5. Connect a fence to the rear shuttles by tightening both screws all the way then loosen them one full turn. Slide the fence all the way back so that it touches the back face of the machine. Adjust the mounts as necessary so that the fence is parallel to the back face.

6. While keeping the rear fence parallel to the back wall, hold down a back mount and tighten its M4 screw. Repeat for the other back mount.

7. Tighten both back fence screws.

8. Tighten the M3 screw on each of the back mounts.

9. Connect the front fence using the same process as the back fence and slide it all the way to the front. Tighten down the M4 screw on each of the front mounts using the same process as the back mounts.

10. Tighten the M3 screw on each of the front mounts.

11. Tighten both front fence screws.

Operation

• The best place to apply a sliding force to each of the shuttles is just to the outside of the dowel. I designed a little tab (more like a nub) at that point. After installing, slide both fences the full travel and make adjustments as necessary.

• The dowel indices should be read by referencing the front face of the shuttles. For example, if you align both back shuttles with the rearmost diamonds, the front face of the back fence (see the blue dot in the image below) will align with the back of the work area.

  

  Since the indices are not aligned for the front fence assembly, make the following adjustments when reading the dowel indices:

  • Back (Inside) face of the front fence (see the blue dot in the image below) is 30 mm more forward than indicated on the dowel. Conversely, the dowel index is 30 mm aft of the intended position.

    

  • Front face of the front fence (see the blue dot in the image below) is 40 mm more forward than indicated on the dowel. Conversely, the dowel index is 40 mm aft of the intended position.

    

• The shuttles can be tightened such that they allow for intentional adjustments while holding their position when weighted down by a workpiece. Of course, they can also be loosened and tightened with each new setup. Your choice!

Questions

Please let me know if you have any questions (Messenger | Printables.com).

Shameless Plug

If this model helped you solve a problem, save some time, or in any way made your life a little easier then please consider clicking the Like button and posting your Makes! If it fell short after clicking on the title of the model, please let me know (Messenger | Printables.com). Either way, Thank you!

Related

   Complete exhaust configuration

      Adapters - Convert machine exhausts to ducting diameter and/or MagDuct

• xTool P2 Exhaust Duct Adapter (configured as 4 in)

• MagDuct xTool F2 Ultra UV Slip Adapter

• MagDuct CORE One Exhaust Adapter and Gasket

      Ducting

• AC Infinity 4" ducting

• AC Infinity 6" ducting

• xTool pipe (included w/ xTool IF2 2.0 and xTool F2 Ultra UV)

• xTool 72.5 mm ducting (included w/ xTool P2)

      Couplers - Convert flexible ducting or pipe/rigid ducting to MagDuct

• MagDuct Flexible Ducting

• MagDuct Pipe/Rigid Ducting

      Connectors - Convert ducting for attachment to inline fan or external surface

• Duct Expander (configured as 4 to 6 in expander)

• Ducting to Window Insert Connector (attached to a piece of 1/4" acrylic inserted in the channels of my double hung windows which allows for quick installation/uninstallation (configured as 148.0 mm (6") and 72.5 mm exhaust port)

      Inline Exhaust Fans

• AC Infinity 6" Inline Fan (High CFM)

• xTool IF2 2.0 Inline Fan (High Static Pressure/Suction)

      Mounts - Securely mount MagDuct components to a surface using a third-party mount

• MagDuct Ring RAM Mount (1 in)

      Accessories

• MagDuct Fume Extraction Nozzle and Screen - Direct smoke and fumes (e.g., soldering) into exhaust ducting

• MagDuct Generic Accessories - Control airflow volume and chamber temperature (e.g., enclosed 3D printers)

   xTool Accessories