RapidChange ATC Improved Pocket Tool

The Problem

1. I found the pocket tool included with the ATC to be a bit “fiddly” to use. One has to precisely align the tool with the notches in the pocket in order to adjust. I have 60 year old eyes and trying to see a black tool in a black pocket and getting everything aligned was a tad frustrating.
2. They include 2 pocket shims that must be dropped into the pocket when using smaller, shorter bits.. Sometimes when I dropped a shim it would drop “on edge” and I would have to fiddle to make it go flat. But the biggest issue is that when you want to remove the shim, you have to completely remove the pocket and then move it upside down so gravity removes the shim. Then you have to re-insert the pocket and adjust it to the same depth. This is far too time-consuming and error prone.

The Solution

1. I re-designed the tool with a couple of changes to make it easier to use. First I made the “handle” wider so I had more grip when twisting the handle with my fingers. The second change was to add a truncated cone to the bottom of the tool so that it would self-align upon insertion into a pocket. You don't have to look and fiddle to align the tool. All you have to do is push the tool into the pocket and twist and it automatically aligns and works. This is a huge ergonomic improvement over the original tool.
2. I added a “tool sleeve” which is basically a cylinder that fits over the the handle of the tool. I also added plugs that have a negative of a M4 washer in the top. One can then super-glue a steel washer to the top of the plug thus making it “magnetic”. To insert a plug, put the “tool sleeve” over the tool handle and then pick up a plug using the magnet at the end of the handle. Lower the plug into the pocket and then push down on the “tool sleeve” and pull up on the “tool” to detach from the magnet and then pull up on the tool sleeve. This inserts a plug into the ATC pocket properly. To remove the plug, just use the magnet on the end of the tool. This is way more time-efficient compared to the original as you don't have to remove, re-insert, and re-adjust the depth of the pocket to remove the plug.

Notes

I have put various sized “magnetic” plugs in a zip file for easier downloading. Please note that depending on how your printer prints, the washer may not fit the end of the plug (ask me how I know).

The end of the tool handle has a depression where you can glue a magnet for easy plug insertion and removal. Magnet size is documented in the OpenSCAD source file (9.6mm diameter, 2.5mm height). You will need to purchase a magnet for the ATC tool. You can use a smaller magnet as long as its diameter is less than 9.6mm.

I am including the OpenSCAD source file so that you can re-generate all of the models with any changes that you desire. Read the comments in the file as they explain how to use the file. You will need to use the source file if the washers don't fit (or if you decide to use a different sized washer or different sized magnet).

Slicing

The atctool requires supports when printing due to the truncated cone on the bottom. You only need to apply supports to the bottom cone / stubs. The rest of the tool is designed with tapers so as to not need supports so just paint supports on the bottom cone / stubs only. The atctoolsleeve and plugs can be printed without supports provided you print in the proper orientation.

Attribution

I based this tool on the original that was included with the RapidChange ATC. I had no access to CAD models of the original so I used a caliper and wrote the OpenSCAD code from scratch.

I have selected “Original Model” as I did not base this on another model file. However, in the end it is just a recreation (with improvements) of a physical object.