Free tool · Pipe layout
Pipe notching template (tube notcher) – printable 1:1 PDF
Enter the diameters of the main pipe and the branch pipe and the angle between them, check the joint in 3D and print a true-to-scale 1:1 PDF template with outer and inner contour. Wrap it around the pipe, scribe, cut – clean saddle joints (fish-mouth cuts) without a notching machine. Works in mm or inch.
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3D preview
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Flat pattern (preview)
Gold = outer contour (scribe line) · dashed blue = inner contour (inside edge of the wall)
Three steps to the template
- Enter the dimensions: outside diameter of the main and the branch pipe, angle and wall thickness. The geometry is calculated immediately.
- Check the preview: the 3D view shows the joint from every side – drag to rotate.
- Print the template: download the PDF, print at actual size, wrap it around the pipe and scribe the line.
Calculate the cope instead of laying it out by hand
Railings, frames, roll cages, pipework or cladding on insulated lines: wherever one round pipe meets another at a right angle or at a slant, the end needs a saddle cut, also called a cope or fish mouth. Instead of constructing the curve with compass and paper, the pipe notcher calculates the flat pattern for your diameters and angle and delivers it as a PDF – with outer and inner contour, quarter marks (0°, 90°, 180°, 270°) and a reference line.
Why an exact fit matters
A tight fit-up is the basis of every good weld. Small errors in the layout lead to large gaps that have to be filled, which costs time and strength. The tool calculates the intersection exactly and gives you a scribe line that fits. We use it every day in our own workshop for railings, handrails and pipe structures.
Help
Frequently asked questions
Is the PDF template really full size?
Yes. The template is drawn in true dimensions. Print with "Actual size" or 100 % scaling and check the scale with the control ruler on the sheet (100 mm or 4 in).
Why does the template show two lines?
The gold line is the outer contour – your scribe line on the pipe surface. The dashed blue line shows where the inside edge of the wall ends. On thick-walled pipe you grind the strip between the two lines at a bevel so the pipe seats on the inside as well as the outside.
What happens with large pipe diameters?
If the circumference is wider than one sheet, the tool spreads the template over several sheets with a glue edge. Choose A4 or US Letter to match your printer.
How is a pipe saddle cut calculated?
For every point around the branch pipe, the tool calculates how far the pipe reaches until it meets the surface of the main pipe. Unrolled over the circumference this gives the typical saddle curve. The tool uses 720 points and draws the outer and inner contour at 1:1.
Can I work in inches?
Yes. Switch the units to inch and enter outside diameters and wall thickness as decimal inches, for example 1.66 for 1-1/4" pipe. Remember that nominal pipe size is not the outside diameter – always measure the pipe.
Does it work for sheet metal cladding on insulated pipe?
Yes. Enter the outside diameter of the cladding for both pipes and the sheet thickness as wall thickness.
Can I use it for miter cuts?
This tool is for branches (tees and angled joints), including pipes of the same diameter. For corners use the pipe miter template, for bends built from several pieces the segmented bend calculator.
How do I cut a saddle joint without a tube notcher?
Print the template, cut it out, wrap it around the pipe and align the reference line square to the pipe axis. Scribe the contour and cut with an angle grinder, a band saw or a file.
Can I get the flat pattern as a DXF file?
Yes. The button "DXF for laser / plasma" saves the flat pattern at 1:1 as a DXF file (format R12) for CAD, laser and plasma software. It contains the outer and inner contour, a separate cut line for cutting on the pipe with a rotary axis (layer RADIAL_CUT), the reference line and the quarter marks on separate layers. A CSV table with rotation angle and axial travel is available as well. In mm mode the drawing unit is millimeters, in inch mode inches. Kerf compensation is not included – set it in your cutting software.