xTool F1 Ultra jig for regular case pocket lighter blanks
With 0.2 mm clearance per side, 3 mm webs and a 5 mm margin, the xTool F1 Ultra's 220 × 220 mm work area fits 15 pockets for regular case pocket lighter blanks, in 3 rows of 5. Staggering the rows does not help with this shape, so the grid is the best layout.
- Blanks per run
- 15
- Layout
- 3 rows of 5
- Blank
- 38.1 × 57.2 × 12.7 mm (1.5 × 2.25 × 0.5 in)
- 38.5 × 57.6 mm
- Clearance
- 0.2 mm per side
- Jig
- Laser-cut 3 mm sheet, through-holes
- Plate
- 220 × 220 mm, 5 mm margin, 3 mm webs
- Tallest point
- 12.7 mm (limit 145 mm)
- Cut path
- 3.67 m
Cut file in millimetres: red = cut, blue = engraved labels and marks. Adjust anything below and download the 3MF, STL, DXF and alignment template.
What to know before you cut
The 0.2 mm starting clearance assumes a laser-cut acrylic, MDF or plywood jig. Cut the test-fit coupon (0.0 to 0.5 mm) in the generator before the full plate: blanks from different suppliers vary, and the laser's kerf makes cut holes slightly larger than drawn.
As a laser-cut 3 mm sheet with through-holes, the blanks rest on the bed or honeycomb and stand 9.7 mm above the sheet.
xTool F1 Ultra is a galvo machine: the field is centred, so the jig is placed in the middle of the 220 mm field and the plate carries engraved centre ticks on each edge to line up with the framing crosshair. Keep the jig the same thickness every time and the focus height stays the same.
The 3 mm corner radius is an estimate; measure one blank and adjust it in the generator if the corners bind.
Adjust this jig
The generator below starts from this machine and blank. Change the clearance, layout or jig build, then download the files.
15 pockets, 3 rows of 5, on a 220 mm × 220 mm plate.
- Pockets
- 15
- Plate
- 220 mm × 220 mm
- Cut path
- 3.67 m
- Sheet used
- 484 cm²
- Tallest point
- 12.7 mm of 145 mm
Cut it
Red = cut, blue = engrave. Millimetre units.
Print it
Through-holes in a plate. Millimetres.
Line up the artwork
Template with pocket centres, blank edge, bleed and safe area, placed where the jig sits on the machine.
Other xTool F1 Ultra jigs
- Military-style dog tag: 18 per run
- Acrylic keychain, 2 in round: 12 per run
Guides
Sources
- xTool F1 Ultra specifications (xTool support) (work area, checked 2026-10-17)
- Zippo Classic Brushed Chrome dimensions (blank size)
Machine and product names are used only to describe compatibility. Pocketplate is not affiliated with xTool.
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