I was looking for a solution that prevents the suction hose and the cable getting caught on the end of the guide rail when sawing with my Festool TS55 saw.

I printed first the excellent model https://www.printables.com/model/350869-festool-rail-deflector-hard-version-fs-aw-with-slo from Yurshevich but I wanted a finer deflector without edge at the rail end that allows to leave the full rail on the workbench when sawing like the original model

I wanted also to keep the idea from Yurshevich to install the clamp on the rail without removing the deflector which is not possible with the original model and also reuse the system to fix the deflector to the rail (Screw, washer and liner)

So I designed in Fusion 360 a new model between both ones

Printing instructions

I decided to use support and print the deflector with the lower part below to have better printing quality with the rounded surface. I never faced issue to remove support generated by PrusaSlicer on my MINI or my MK3S

Note that deflector size is compatible with MINI bed size. Just rotate deflector 45 degrees

I printed the deflector in Prusament PLA Jet Black with 0.20mm layer height and 4 perimeters. he other parameters the the default ones from PrusaSlicer

The screw, washer and liner were also printed in PLA with 0.10mm layer height for better quality for the threads

Result is perfect. Deflector fits well to the Festool rail. Cable and vacuum hose slip on it without problem

EDIT 27/08/2023

Following remark from a maker → https://www.printables.com/model/504664-deflector-for-festool-fs2-guide-rail-remix/comments/929855 , I reinforce the part where to insert the clamp. The lower part is a bit thicker than the original version (1.6mm instead of 1.2) and the space to pass the clamp has been adjusted

New version → 

Previous version → 

On top of .3mf and .stl files I uploaded Fusion 360 .f3d one so you can modify the design and adapt it to your needs

As usual, feedback and comments (and for sure "likes") will be always welcome. Feel free to post nice pictures of your makes

You can also look at the other Festool accessories I designed and 3D printed

• Festool TS55 anti-tilt stops
• Festool TS55 REBQ dust cover
• Guide stop for Festool rail FS/2 and knob
• Festool knob V2
• Festool TS55 vacuum hose connector
• Festool clamp FS serie protective pads
• FESTBOX a cool box to be hanged to your Festool Systainer with Gridfinity Compatible Model
• Systainer SYS3 Lid Alignment Guides
• Systainer T-Loc Lid Alignment Guides

Enjoy

If you like this model, take a look also at my other designs