Making bigger router templates

I have a 20W diode 450mm^2 Twotrees TTS-20 Pro with 419x419mm cutting area. I want to cut router templates bigger than the cut area of my laser engraver. I use 1/4" (6mm) MDF for routing templates.

I’m thinking that if I break up the pieces with jigsaw-like lines, then I can snap the smaller pieces together into a bigger template.

Has anyone done this before? Any tips or tricks to keep the dimensions accurate? Any tips on the best shapes to lock the pieces together - sharp corners vs rounded corners?

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Yes it can be done hat way, but have a look at Print and Cut feature

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larger pieces won’t fit in my enclosure

ok, I cut T shapes and slots to join pieces like that, I find it easier to accurate joins with them.



I haven’t done that, yet, but there is (or at least used to be) a lot of examples of that method in DIY woodworking circles.

Works extremely well.
The reason why it works so well is that the master template is only used for making work-templates out of more durable materials, never to actually route the workpiece with.
And if it’s just for a one-off use, it’ll withstand that.

The reasons why that method is used is mainly twofold.

#1 While the cut areas of the machines the master templates are cut/routed with are always somewhat limited in size, there’s no limit how big a template someone would want/need.

#2 Shipping costs skyrocket as the shipping dimensions get larger.

There are many other reasons one can think as well, but those two are IMO/IME the most relevant ones.

Engrave markers on the pieces so You can check the dimensions when assembling the master template.


Cut accurate holes on the master template pieces and use those to check the dimensions and to fasten the template to the work template to be routed.

That depends on the accuracy demands and the size of the template pieces.
As well as the material of the templates.

T-slots @Wyked mentioned and other straight sided shapes have the added benefit to act as dimensional checking aids.
OTOH, T-slots pretty much have to be at least ~2x the material thickness at the narrowest dimension though, otherwise they snap off rather easily if the fit is tight.



Worked like a champ for a big quilting template:

The pieces just barely fit on the platform:

Packing tape surely won’t work for your templates:

Quick and easy and the quilt came out fine!

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