Making a Tool Holder on the xsTECH CNC Desktop Router: Parts 4, 5 & 6

In the first half of this project, we prepared and faced the material, then cut the rectangular profile for a custom tool holder on Tormach's xsTECH CNC desktop router. Now in parts 4 and 5, we move into creating the functional features of the design. Part 4 covers pocketing for collet nuts and collets, while part 5 adds pockets for endmill cases. By the end of this stage, the tool holder will have precision-fit spaces for organized storage and quick tool changes.

Part 4 – Collet Nut and Collet Pockets for the xstech tool holder

The collet nut pockets begin with a standard ER11 collet nut. Since a tight press fit is not required, the pocket diameter is set at 19.45 mm, with a Z start of -1 mm from the previously faced surface and a Z end of -4 mm for enough depth to seat the nut. Depth of cut is 2 mm, stepping down in 1 mm passes at 500 mm/min feed rate. The pockets are laid out in a pattern starting at X 50 mm and Y 30 mm, with evenly spaced X positions at 50, 75, 100, and 125 mm while keeping the same Y coordinate for all.

The collet pockets use the same pattern but require a tighter fit. The pocket diameter is reduced to 8.1 mm to hold the collet securely. These pockets start at Z -3 mm and extend to Z -11 mm to keep the base intact. Depth of cut is set at 2.5 mm, stepping down in 1 mm increments. Both operations use the same G54 work offset, tool number 3, and spindle speed of around 15,400 RPM.

By using conversational editing in PathPilot^®, existing programs can be quickly modified rather than recreated from scratch. This makes it easy to adjust dimensions or drilling patterns as needed. An optional stop command (M1) is included after the first set of pockets, allowing time to vacuum chips before moving to deeper cuts. This is especially useful in a classroom or small-shop setting where keeping the work area clean helps maintain accuracy.

Part 5 – Endmill Case Pockets for xstech tool holder

The final operation in this phase is creating pockets for endmill cases. These pockets are designed to hold the bases of endmill storage cases securely so they can be removed and replaced as needed without tipping over. After measuring for a snug fit, the pocket dimensions are set to 12.84 mm by 12.84 mm with a corner radius of 1 mm. The Z start is -1 mm and the Z end is -10 mm for adequate depth.

The pockets are arranged in a pattern with X positions at 47, 67, 87, 107, and 127 mm, all sharing a Y position of 68 mm from the origin. This setup allows for five pockets across the tool holder, but the number can be adjusted depending on the user’s needs. The operation uses a rectangular pocketing strategy in PathPilot with a 4.5 mm depth of cut, splitting the total depth into two passes. Stepover is set at 17 percent for efficient material removal without excessive tool load.

Before running the program, it is important to confirm the machine’s unit settings. In this case, a recent PathPilot update had defaulted to G20 (inches), which caused caution messages in earlier operations. Switching to G21 (metric) in the MDI bar ensured consistent measurements and eliminated conflicts between metric programming and machine settings.

Once the pockets are cut, the tool holder has designated spaces for collet nuts, collets, and endmill cases, making it easier to keep tools organized and ready for use. This completes the functional machining for the tool holder’s main storage features. The next steps will focus on labeling, finishing, and any additional customization to make the holder even more efficient for its intended use with your xsTECH desktop router.

Part 6 – Engraving the Tool Holder on the xsTECH

The final step in this stage is adding engraved text to the tool holder for clear labeling and personalization. Using a viewpoint engraving tool (tool 33), the text height is set to 12 mm and positioned from the center of the workpiece for balanced placement. The X base position is 87 mm and the Y base is 43 mm, chosen to center the text within the available space.

Before cutting into the material, a test pass is run 5 mm above the surface to confirm that the engraving will be aligned properly and positioned within the designated area. This precaution is especially important since engraving is often the last operation in a project and mistakes at this stage can be difficult to correct.

The engraving process uses the same G54 work offset established earlier. Spindle speed is set to 15,000 RPM with a feed rate of 400 mm/min, and a clearance height of 15 mm is maintained to avoid clamps or other obstructions. After the initial pass, the depth is evaluated at 0.15 mm. Since a deeper engraving is desired, the program is adjusted to increase the depth while keeping the same location and alignment. This approach allows for refining the final look without risking misalignment.

Once complete, the engraved labeling adds a professional finish to the xsTECH tool holder while improving organization. Combined with the precision-fit pockets from earlier steps, the tool holder is now both functional and customized, ready for classroom or small-shop use.