Better Xacto Knife Handles (now With V2)

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Introduction: Better Xacto Knife Handles (now With V2)

About: I'm a high school senior who loves to make stuff. I love unicorns, neopixels, anything that fires something, and food ;)

I created these handles in order compensate for an Xacto blade's angle. As shown in the second photo, this makes the cutting edge steeper, which is better when doing precision cutting as it keeps the point downward without the need to uncomfortably hold your hand upright. A resin printer will likely yield the best results, but I printed this on my Prusa MK2.5S and it turned out great.

The following steps explain how to assemble the keychain Xacto knife; to assemble the full-length version, just follow the same steps, omitting the loop.

Supplies

Filament (I used PLA)

one M2*4mm screw

one M2 washer

one M2 nut

Xacto blade

M2 allen wrench

loop of some kind (I used some dog tag chain)

Step 1: Printing the Handle and Cap

Update 10/29/20: I have created a much stronger and more functional design for the purpose of FDM printing, but it still has the same assembly instructions.

Xacto Handle V1 files and info here: https://www.prusaprinters.org/prints/41096-v1-bett...

Xacto Handle V2 files and info here: https://www.prusaprinters.org/prints/41102-v2-bet...

V1 Print instructions

As mentioned before, I printed my parts in PLA on my Prusa MK2.5S.

Print the files at 103% scale, with a 0.1mm layer height, 2 perimeters, 20% infill, and a brim.

Do whatever PLA temps you prefer.

For the long handle, slow down your print speeds.

V2 Print instructions

Use whatever settings you prefer! The handle is already scaled, and since it prints flat on the bed, you don't need any special settings.

For reference, I used 0.2 mm layers height, 2 perimeters, 20% infill. Optionally, use a brim. You will need to cut/drill out some material from the bolt hole, which is there to prevent the need for support material.

Step 2: Gather Your Parts

Make sure you have the following:

Full length or keychain handle

Cap

M2*4mm bolt

M2 nut

M2 washer

M2 allen wrench

Loop of choice

Step 3: Inserting the Nut

Take the handle and insert the nut as shown in the first photo. If you can press it in manually, that great! My print was snug, so I simply took the screw and allen wrench and tightened the screw. Once the nut was flush with the back of the print, as shown in the third photo, unscrew the screw.

Step 4: Insert Blade

Take your blade of choice and in place it so the sharp edge lines up with the handle and the blade's hole lines up with the screw hole. Holding the blade, place your washer on the screw and insert it into the hole in the blade and tighten.

Step 5: Cap and Loop

The cap is not centered on the blade, so in order for it to fit, you need to flip it the right way. If you get it on the wrong way, just turn it around and the blade will slip into its corresponding hole. Adding the loop is as simple as feeding it through the hole and connecting/tying it.

Step 6: Conclusion

Congrats! Now you have an Xacto knife that cuts more efficiently than a normal handle. I like to keep a couple of these around the house and one on my backpack, just in case.

If you could vote for me in the 3D printing contest, my high-school-senior-self would greatly appreciate it!

Cheers

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    6 Comments

    0
    crazypj
    crazypj

    1 year ago on Step 6

    I don't have a 3D printer and it's pretty doubtful I'll ever have one? (never say never -LOL)
    Anyway, I still think it's a great idea to have blade fixed at a 'better' more user friendly angle.
    I'm almost certain I can make something very similar in stainless steel, it will take rather a lot longer than printing though. ;o)
    BTW, how do you prevent the blade guard falling off? I would imagine encapsulating a small neodymium magnet (3x1mm?)would prevent any movement?

    0
    matthew.legates
    matthew.legates

    Reply 1 year ago

    I'm glad you like my idea! Having a stainless steel one sounds so cool! To answer your question, the blade guard is friction fit; I designed it with 3D print tolerances in mind, so it's fairly snug. I thought about adding a magnet, but I wanted to keep the cap relatively thin, and I didn't have any thin magnets on hand. I took some design elements from Xacto's blade caps, and unless you put your design through the washer (heh), it will stay on for a good long while.
    If you do end up making a stainless steel one, you might be better off making plastic cap, as the plastic can bend and hold onto the handle really well

    0
    manuelmasc
    manuelmasc

    1 year ago

    Very nice, voted! I'll try to print it as soon as I'll be able to access my 3d printer

    0
    Icelandian
    Icelandian

    1 year ago

    Nice design. Xacto should pay you to license it.

    0
    Penolopy Bulnick
    Penolopy Bulnick

    1 year ago

    That's a good design for an xacto knife :)
    Did you use Fusion 360 to design it?

    0
    matthew.legates
    matthew.legates

    Reply 1 year ago

    Why yes, I did! Though as of now, I still consider myself a novice at it :P