3D Printed Glass Bottle Cutting Tool

Hello Makers,

with this instructable i want to give you the opportunity to make your own tool for cutting glass bottles. I am new to 3D-printing and wanted to prove that it is possible to create a more complex tool with this technique. Also i hope i can give you an imagination of what you are able to do with 3D-printing beside of producing statues. Let´s start!

Step 1: Tools and Materials

Here is a list of what you need to build this tool.

Tools:

1. 3D-printer
2. screwdriver
3. metal saw
4. deburrer or sharp knive
5. file
6. pliers

Materials:

1. PLA filament (about 200g)
2. 1x standard screw (M6x50 DIN EN ISO 4017)
3. 5x standard nuts (M6 DIN EN ISO 4032)
4. 2x M6 threaded rod (320mm)
5. 7x wood screw (3x12mm)
6. 16x o-ring (inner-Ø 17mm; thickness: 3mm)
7. 1x (aluminium-) pipe (8x1mm; about 300mm)
8. 1x spring (should fit around an m6 screw; max. outer-Ø 10mm; 10mm length; about 80N of force)
9. glass cutting blade

You can get most of the materials in your local hardware store. Otherwise you can order them online.

For the glass cutting blade i use this one:

https://www.ebay.de/itm/1-WORLD-TOOL-Ersatz-Glas-F...

You might want to use another one or one from your local hardware store. Therefore i will give you the dimensions of the tool (PDF) holder so you can customize it.

Step 2: Printing

To built a tool it is necessary to have precise and robust parts. That's why it took me about 23h to print everything. I uploaded the single parts and recommend the following settings:

(Keep in mind that your printer might be totally different to mine, which makes it necessary for you to check your settings and maybe to customize them before printing)

For case A/B and case cover A/B:

• layer height: 0,1mm
• infill: 20%
• speed: 60mm/s

For the star grips and wheels:

• layer height: 0,15mm
• infill 20%
• speed: 60mm/s

For the tool holder:

• layer height: 0,1mm
• infill: 20%
• speed: 50mm/s
• support: overhang angle: 80°; pattern: lines; density: 8% (compare with picture)

Step 3: Preparing the Other Parts

While you are printing you can prepare some additional components:

• use the metal saw to cut the threaded rod into two 160mm long pieces
• cut the pipe into eight 27mm long pieces and two 25mm long pieces
• use the file to deburr the edges of the pipes and the threaded rod

tipp: use a bench vice, but be careful not to deform the pipe

Step 4: Assembly Step 1: Post-processing

1. check all the parts if they are correctly printed
2. remove the brim with the deburrer or sharp knive
3. remove the support from the tool holder with the help of pliers

Step 5: Assembly Step 2: Wheels

1. put the o-rings onto the wheels and
2. insert the 27mm pipes

Step 6: Assembly Step 3: Star Grips B

1. Insert the nuts into the two star grips B

Step 7: Assembly Step 4: Tool Holder

1. insert the M6x45 screw in the star grip A
2. press the glass cutting tool into the square hole of the tool holder
3. install the nut and spring in the shaft of the tool holder with the help of pliers

Step 8: Assembly Step 5: Case A

1. insert the nuts in the shafts of case A
2. screw the threaded rods into the nuts of case A until they fit tightly
3. place the star grip A in the bearing position
4. slide the tool holder into the rail of case A
5. screw in star grip A

Step 9: Assembly Step 6: Case B

1. press the two 25mm pipes into the holes of case B

Step 10: Assembly Step 7: Case Cover

1. place the assembled wheels in the holes of case A and case B
2. click case cover A onto case A and make sure the pipes slide into the holes of case cover A
3. click case cover B onto case B
4. screw in the wood screws to hold the covers in place (be careful about the torque; alternatively you can glue)

Step 11: Assembly Step 8: Wedding

1. slide case B onto the threaded rods to combine the two cases
2. screw on the two star grips B

Step 12: Testing and Handling

Before you start with your "glass bottle project", you should grab some old bottles to test the tool and to learn how it works the best way.

Attention: You should wear safety gloves and glasses to avoid injuries. Also you will use boiling water. Be careful!

How it works:

1. mark a cutting line on the surface of the glass bottle and remove the label
2. make sure the cutting blade is retracted
3. position the tool around the bottle
4. use carbide sandpaper to sand the sharp edges
5. use alterningly hot and cold water on the score line to create tension...the bottle will split at the score line
6. remove the tool by loosening the screws
7. retract the the cutting blade again
8. turn the tool one time around the glass bottle until you reach the starting point
9. if the blade doesn't score, adjust with the star grip
10. screw the star grip to drive out the cutting blade until it presses onto the bottles surface
11. turn the tool a couple of times around the bottle to position the wheels correctly
12. screw on the two star grips to clamp the tool (the wheels should still turn smoothly)

Thank you for your interest and enjoy!