This is a universal-fit end cap for 4080 T-slot aluminum extrusion profiles, designed to fit most common 4080 systems (Bosch, Item, Motedis, OpenBuilds, etc.).

It can also be used as a flat connector between two 4040 profiles placed side by side, allowing modular frame expansion or wide base construction.

The design features rounded outer corners that match the natural contour of T-slot extrusions, giving a smooth, professional finish.

It uses a friction-fit connection, staying firmly in place without screws or glue.

Because internal dimensions vary slightly between manufacturers, you may need to adjust tolerances (±0.1–0.2 mm) in your slicer for a perfect fit.

✅ Features

Compatible with most 4080 and 4040 T-slot profiles

Functions as both end cap and side connector

Rounded corners for a polished, OEM-style look

Friction-fit connection, tool-free installation

Tolerance-friendly design — slicer adjustment ±0.1–0.2 mm

Printable flat, no supports required

🧰 Applications

End protection for 4080 frames

Joining two 4040 profiles side by side

Base frame extensions and reinforcements

CNC, printer, or furniture frame builds

🛠 Recommended Print Settings

Material: PETG / ABS for functional use, PLA for light-duty

Layer Height: 0.2 mm

Infill: 50–100 %

Supports: Not required

Orientation: Flat on bed

📏 Compatibility

Works with T-slot 4080 extrusions (Bosch, Item, Motedis, OpenBuilds)

Can connect two 4040 profiles side by side

May require tolerance tuning (±0.1–0.2 mm)

Not recommended for Misumi extrusions

T-Slot 4080 End Cap (Universal Fit, Connector)

0.2mm layer, 2 walls, 15% infill

0.2mm layer, 2 walls, 15% infill