Pin header cutter

This tool is created to help cutting pin headers that don't cut nicely with side cutters. Some headers are too wide to fit the cutters properly or might miss the cutting aids causing the plastic to shatter randomly.

The design is modular and various adapters can be created to suit different hardware and header types.

The design

Tool uses linear ball bearing for smooth operation, but some adapters can be made for other type of linear guiding. E.g. brass bushings or simple plastic bearings. These adapters or versions are not included in this design at the moment.

Blade holder is a separate part to the linear mechanism. Its purpose is so that the blade can be easily changed and different adapters can be made for different blade types. These adapters or versions are not included in this design at the moment.

A plastic lever is included in the design, but a metal version can be made. I have found that the plastic one is sufficient. For smooth operation, a piece of steel axle is added to the linear mechanism for facing the lever action. The lever slides slightly while pressing to the mechanism and printed plastic might deform without the axle.

The header tray is detachable and the included version works for double row 2.54 mm pitch header. To support the header while cutting, a plastic part is included in the design, but I have made a one from FR4 PCB. It is important to open the holes from the point header is cut. The opening allow the header to move horizontally when the cutting is done.

Stopper can be printed from PLA or TPU for smoother stopping power. The purpose of the stoppers are to stop the linear motion before the blade hits the static part. This saves the blade.

The heated inserts in linear mechanism can be shouldered one or wihtout. The design is made for shouldered ones.

Needed hardware

This build requires some special hardware 

• 1 pc, Stanley 11-987 knive blade (55.4 mm wide)
• 2 pcs, LM5UU (5x10x15) linear bearing
• 2 pcs, d5 mm x 65 mm steel axle
• 1 pc, d5 mm x 18 mm steel axle
• 1 pc, M5 x 20 mm
• 1 pc, d5-M4, 20mm shoulder screw
• 1 pc, M4 lock nut
• 4 pcs, M3 x 8 mm countersink screw
• 4 pcs, M3 x 6 mm countersink screw
• 2 pcs, M3 x 10 mm countersink screw
• 2 pcs, M3 heated inserts
• 2 pcs, springs with at least 5 mm inner diameter, 20-25 mm length

Drawings of the blade if the exact blade cannot be sourced.

Shoulder screw