Making a Tool Holder on the xsTECH Desktop Router: Parts 1, 2 & 3

Creating a custom tool holder is a practical project that helps organize collets, tools, and accessories for specific machining tasks. In the first three parts of our five-part series, we will cover setup, facing the material, and cutting the rectangular profile on the Tormach xsTECH desktop router. By the end of part 3, you will have a tool holder blank ready for detailed machining in parts 4 and 5 (which will be published next week). This process is ideal for classroom instruction, small shops, or hobbyists looking to keep tooling organized and project-ready.

Part 1 – Setup and Facing the Material on the xsTECH

The initial design of the tool holder can be as simple or complex as needed. One version included multiple tool slots, while a refined design focused on fewer slots and dedicated collet holders. The collet pockets are designed to fit slightly tight so they grip securely. This allows the lid and base of a collet to stay together, making it easy to swap out sets for specific projects. For example, one tool holder might be dedicated to engraving tools with smaller-diameter end mills, while another holds larger cutters for general machining.

The project begins with a 7-inch by 3.5-inch material block that needs to be faced for a smooth, flat surface. Workholding is planned so clamps stay clear of the toolpath, with safe zones marked at 19 mm from the zero corner. Using PathPilot® conversational mode, the facing operation is programmed with conservative feeds — 500 mm/min with the option to increase using feed override. Tool number 3 is selected, spindle speed is set to 15,000 RPM, and a 1 mm depth of cut is chosen for a clean surface finish. Z clearance is set to 30 mm to avoid clamps, and the program is saved in the project folder before moving to the machine.

Part 2 – Material Setup for Facing on The xsTECH

For Z-zeroing on the xsTECH, a practical visual method is used: watching the tip of the cutter meet its shadow on the workpiece surface under light. This gives a quick and reasonably accurate reference without needing to rely solely on the paper method. The G54 work coordinate system is set to retain X and Y positions, even if the machine is shut down between operations.

With the facing program loaded and no error indicators in PathPilot, the cut begins at a reduced feed rate for safety, then increases to full speed as the operation proves stable. The single-flute cutter handles the wood smoothly, with feed rate adjustments up to 700 mm/min for optimal chip formation. The facing pass takes about 19 minutes, producing a flat, clean surface ready for the next operation.

Part 3 – Cutting the Rectangular Profile

The rectangular profile defines the outer shape of the tool holder. The starting X coordinate is set at 25 mm to allow clearance for the cutter, with the profile extending to 147 mm. Corners are given a 4 mm radius, and the Y start is set at 88 mm, ending at 4 mm from the opposite edge. This ensures even margins and smooth outer edges.

Since the material has already been faced by 1 mm, the Z start is set to -1 mm, with the cut extending down an additional 12 mm for thickness. This operation uses the same G54 work offset, spindle speed of 15,000 RPM, and a safe 500 mm/min feed rate for the initial full-width pass. Depth of cut is 1 mm per pass, and the program is posted to the same project folder.

On the xsTECH, the rectangular profile is loaded and run. The first pass removes the full-width material around the perimeter, followed by lighter stepovers to bring the tool holder blank to final dimensions. While the facing took about 19 minutes, the profile cut is expected to take longer due to the full-depth engagement and multiple passes required.

By the end of part 3, the tool holder blank is fully surfaced and shaped. In the next week's article, we will cover the pocketing and finishing operations that turn the blank into a fully functional tool holder with precise collet slots and labeled sections for organized tooling.