Infinite Assembly System for 45x45 Aluminum Profiles

Infinite Assembly System & Templates for 45x45 Aluminum Profiles (Bosch Type - 10mm Slot)

This project provides you with a set of essential tools and guides for working cleanly with 45x45 mm (10mm slot) profiles. Whether for designing robust frames or custom structures, this system is designed for demanding workshops, professionals, and makers.

The project consists of two complementary and ingenious elements:

• 45x45 Extension Profiles (customizable lengths) : These models reproduce the shape of aluminum profiles to allow you to print spare sections or specific supports. Several lengths are already positioned on the build plates. Tip : You can create the exact length you need by simply modifying the Z-axis height in your slicer, without touching the X and Y dimensions.
• Guiding and Joining Inserts : Designed to bypass the size limits of our 3D printers! These inserts slide perfectly into the 10 mm slots to assemble your profiles end-to-end and obtain perfectly aligned long lengths. You will only need to tap the holes to M6 to finalize an invisible and ultra-rigid assembly.

Design Highlights :

• Adjusted Tolerances : Designed to slide precisely and without play into standard Bosch type 45x45 slots.
• Workshop Precision : Ideal for creating invisible connections or perfect square assemblies, without requiring complex metrology tools.
• Economical & Reusable : An excellent alternative to expensive commercial positioning parts.

Required Material & Hardware (BOM)

To properly prepare and assemble your parts after printing :

• Tapping : The holes in the linear inserts are pre-drilled to the correct diameter. They must be manually threaded using an M6 tap.
• Screws (per insert) : Provide 4x headless screws (grub screws) M6 x 12 mm to ensure a firm, powerful, and completely flush lock in the slot.
• 🔧 Assembly tool : A standard Allen key or a T-handle wrench to easily screw and adjust your grub screws through the guide openings.