Flite Test Inspired foam board cutter jig

thingiverse

Flite test has revolutionized the hobby of model aircraft for the world, and its creators have helped make it accessible to everyone. The most challenging aspect of precision cutting is mastering the bevel, but one skilled craftsman, Bixler, can cut perfect bevels blindfolded while standing on his head with a razor held between his teeth - a feat that leaves others in awe. I am still far from achieving such perfection, and as my flying skills improve, I find myself making fewer parts and repairs, which unfortunately leads to a decline in my beveling skills. When it's time to create something new, all my cuts are clumsy and unsatisfactory. I decided to take matters into my own hands and embarked on a long journey of testing and developing this innovative tool. Its flexible hinge area allows for effortless adjustments when dealing with slight variations in foam thickness, while also providing a secure grip as you cut through the material. This versatile tool excels at both single and double bevel cuts. However, when working with single sheets of foam, a scrap piece of foam is required to place underneath the tool, which was designed for use with double sheets. To ensure maximum usability, I recommend printing this tool in both left-handed and right-handed versions, as there are instances where the finger grip may hinder completion of a cut. In such cases, simply swap out the tool with its opposite counterpart to finish the task at hand. The blade can be carefully laid flat on the surface of the tool and gently pulled or used with a slight sawing action to achieve precise cuts through the foam. Be cautious not to angle the blade too high, as this may cause it to dig into the tool over time. I have successfully utilized this tool for cutting four wings and numerous control surfaces without experiencing any wear on the paper. My goal is to alleviate frustration associated with beveling and make this process more manageable for everyone involved. I am eager to gather feedback from real-world users, who will help me identify areas of improvement or redesign opportunities that can further refine this tool's functionality. By sharing this design with friends, I have yet to receive any complaints, which suggests its effectiveness in simplifying the beveling process. During testing, I discovered that printing these tools in ABS and PLA yields satisfactory results from both materials. While I slightly prefer the feel and appearance of ABS over standard PLA, it does introduce a bit more flexibility to the joint, making it easier to work with.