Aluminum Profile become Woodworking Cutting Guide

This project is a set of 3D-printed components designed to build a woodworking circular saw cutting guide.
When assembled with 2020 aluminum extrusion, it forms a rigid and precise guide that helps improve cutting accuracy and consistency.

The guide is designed for modular assembly using standard hardware, making it easy to build, adjust, and integrate into different workshop setups. It is suitable for DIY woodworkers, makers, and anyone looking for a practical, functional 3D-printed jig.

Key Features

1. Designed for 2020 aluminum extrusion
   The printed parts mount directly onto standard 2020 aluminum profiles, providing excellent rigidity and alignment.
2. Adjustable cutting angles
   Supports 45°, 60°, and 90° cutting angles, covering common woodworking needs.
3. Accurate and repeatable cuts
   The combination of aluminum extrusion and printed guides helps maintain straight, consistent cuts.
4. Modular and adjustable design
   Easy to reposition, fine-tune, or expand using additional extrusion or printed parts.
5. Functional 3D-printed workshop tool
   A practical example of combining 3D printing with real-world woodworking applications.

Required Hardware

To complete the assembly, the following hardware is required:

• M5 × 18 socket head bolts × 3
• M5 T-slot nuts × 5
• M5 × 20 hex head bolts × 2
• M5 × 6 socket set screw × 2 or 3 (to lock the thin guide plate from the buttom, securing it firmly in position and preventing movement during cutting operations)

(Standard 2020 aluminum extrusion is also required and not included.)

Why 2020 Aluminum Extrusion

2020 aluminum extrusion is widely used in workshops because it offers an excellent balance of strength, precision, and modularity.
The standardized T-slot profile allows secure mounting and accurate alignment, making it ideal for cutting guides and jigs.

By combining 3D-printed parts with aluminum extrusion, this cutting guide achieves greater rigidity and dimensional stability than fully printed guides. At the same time, the modular nature of extrusion makes the system easy to adjust, extend, or repair using widely available components.

This hybrid approach delivers the flexibility of 3D printing with the reliability of aluminum, resulting in a practical and precise woodworking tool.

Printing Notes

• PLA or PETG is recommended
• Dimensional accuracy is important for best performance
• Light sanding may be used to fine-tune fit if needed

Perfect For

• Woodworking workshops
• DIY makers and hobbyists
• Circular saw cutting guides and jigs
• Functional and practical 3D prints

Community & Feedback

If you build this cutting guide or customize it for your setup, feel free to share photos and feedback in the comments. Improvements and variations are always welcome.