June 28, 2026
Description
This is a premium, heavy-duty jig system designed to let you cut flawless, smooth corner radiuses quickly and safely. It features four of the most common shop radiuses (1/4", 1/2", 3/4", and 1") in a single, compact tool.
You can use the template on its own to draft quick pencil lines, or snap on the ergonomic registration handle to use it directly with a flush-trim bit on your router table or with a handheld router—no layout lines required!
Solid Template: A full 1/4" thick plate for maximum rigidity.
Center-Recessed Template: Features a 1/8" deep cutout in the center. This saves filament and creates a handy recess to hold router bits or small parts on your bench.
Two-Tone Center Fill: If you like the solid 1/4" feel but want a custom look, you can print this insert in a contrasting color to glue into the recessed template.
Ergonomic Handle: Includes variants to print with or without the extra-grip backplate.
Pro-Tip: For maximum safety and stability, apply a piece of high-friction rubber, 220-grit adhesive sandpaper, or non-slip tape to the underside of the template. Combined with the handle, it will lock onto your workpiece and completely eliminate slipping.
Dual-Purpose Registration Tabs: The handle tabs slip effortlessly into the template slots while simultaneously acting as edge stops that automatically square the template perfectly to your workpiece corners.
High-Visibility Markings: Clean, easy-to-read debossed size callouts on every corner make choosing the right radius instant.
Foolproof Operation: A crisp feed-direction arrow is integrated right onto the handle to ensure you are always routing safely against the rotation of the bit.
Versatile Workflows: Engineered specifically for use with flush-trim bits (bearing guided) on router tables or handheld setups.
Filament Saver: The optional center-cut version reduces print time and material usage without sacrificing structural integrity.
Main Plate: 6” x 6” square (plus 0.5” extension for the side tabs) x 0.25” thick.
Alignment Tabs: 0.5” wide x 1.377” long.
Center Recess: 4” x 4” square x 0.125” deep.
Handle Assembly: 7.278” long x 2.005” wide x 0.25” thick (features a 0.125” deep finger groove with an optional 0.25” x 4.5” backplate).
Material: ABS, ASA, or PETG (Highly recommended for workshop durability and impact resistance).
Infill: 50% to 100% (Higher infill recommended for the handle and perimeter to withstand router bearing pressure).
Walls/Perimeters: 4–6 lines (Crucial for ensuring the outer template edge is completely solid for the router bearing).
Supports: None required.
Orientation Notes
Template & Handle: Print flat on the build plate exactly as oriented in the files.
Connecting Pins/Tabs & Infill: Rotate these 90 degrees so the flat side (the side without the radius) sits directly down on the build plate. This ensures maximum shear strength along the layer lines when snapped together.
Assembly is quick and straightforward, requiring just a few drops of CA glue (super glue) or epoxy.
Test Fit: Clean up any minor elephant's foot or print artifacts with a hobby knife if necessary. Dry-fit the connecting pins and alignment tabs into the handle slots to ensure a snug fit.
Orient the Tabs: Ensure the flat, non-radiused side of the pins sits correctly down against the registration slots.
Glue and Clamp: Apply a small amount of plastic-compatible glue to the pins/tabs, press them firmly into the handle assembly, and allow them to fully cure before use.
Custom Requests
If you need a version of this template featuring different or metric radiuses, drop a comment below with your requested sizes and I will do my best to upload a variant for you!
License:
Creative Commons — Attribution — Noncommercial — Share Alike
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