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.
Open the calculatorOnline pipe notching calculator
3D preview
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Drag to rotate, scroll or pinch to zoom. Gold line = cut contour on the branch.
Flat pattern (preview)
Gold = outer contour (scribe line) · dashed blue = inner contour (inside edge of the wall) · Move the pointer or your finger along it to read angle and height.
Applying the template
Loading 3D preview …
Print side out, reference line (blue) towards the pipe end, ends meet at 0° / 360°. The gold edge is your scribe line.
Hole in the main pipe (preview)
Not needed for railings and frames – the branch is only set on and the main pipe stays closed. The main pipe needs a hole only for pipework (water, air or exhaust flows through) or if the branch is pushed into the main pipe.
When shown, it is added as a second sheet to the PDF and the DXF.
Version 3.0 · Oct 15, 2026 · What’s new?
- Version 3.0, Oct 15, 2026
- Rectangular tube as main member and branch, plate as main member (with opening on top and underside)
- Several equal branches with one marking template for the main member
- Cut length from the axis length and a cut list, also with both ends notched
- Share link with all inputs
- Print correction: enter the measured ruler, the PDF compensates the printer
- Version 2.0, Oct 15, 2026
- Offset from center (up to flush) and weld gap
- Template for the hole in the main pipe (PDF and DXF)
- Tube notcher settings: hole saw, swing angle, offset
- Standard pipe list (NPS) and angle slider
- Flat pattern with dimensions and a read-out line for angle and height
- New view “Applying the template”, pipes shown with wall, selectable finish
- Large pipes: the PDF is also split over several sheets in height
- File names include offset and gap; version in PDF, DXF and CSV
- Version 1.3, Oct 5, 2026
- DXF for laser and plasma with radial cut
- Rotation / travel table as CSV
- Version 1.2, Oct 4, 2026
- English version with inch and US Letter
- Version 1.1, Oct 3, 2026
- Logo on the PDF template
- Version 1.0, Oct 1, 2026
- New website: 1:1 PDF with outer and inner contour, quarter marks, several sheets with glue edge, 3D preview
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. A second view shows how the printed template is wrapped around the pipe.
- 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.
Offset branch, weld gap and hole in the main pipe
Under "More options" the pipe notcher also handles cases that are hard to lay out by hand:
- Offset: the branch sits off center – up to flush with the outside of the main pipe. The saddle curve becomes asymmetric and much deeper.
- Weld gap: an even gap between the pipes, for example for a full-penetration weld. It is calculated as if the main pipe were larger by the gap.
- Hole in the main pipe: a second template that is wrapped around the main pipe – for set-through branches and for branches that something flows through.
- Hole saw: if you work with a tube notcher, read hole saw diameter, swing angle and offset below the flat pattern.
- Rectangular tube and plate: round on square tube, square on round, rectangular on rectangular and pipe on plate – with opening on top and underside of the plate.
- Several branches: for example balusters at equal spacing, with one marking template for the rail.
- Cut length and cut list: the stock length of the branch from the axis length, also with both ends notched.
- Link and print correction: share all inputs as a link; if the ruler on your print is not exactly 4 in / 100 mm, the next PDF compensates the printer.
Step by step: how to use the template
- Print: print the PDF at "Actual size" or 100 % – not "Fit to page".
- Check the scale: the control ruler on the sheet must measure exactly 100 mm or 4 in. If it does not, the print settings are wrong.
- Cut out: cut along the gold outer contour and keep the straight reference line at the bottom. With several sheets, join them at the glue edge.
- Wrap: wrap the template tightly around the branch pipe, print side out, with the reference line square to the pipe axis and the ends meeting at 0° and 360°.
- Align: transfer the quarter marks to the pipe. On a centered branch the lowest point of the curve is at 0°, the highest at 180° – use this to align the template with the slope on angled joints.
- Scribe and cut: trace the contour with a scriber or a fine marker, cut with an angle grinder, band saw or file and finish down to the blue inner contour.
Common pipe combinations
Cut depth (outer contour) and pattern length for common railing and frame pipes (NPS outside diameters), centered, no gap. For other sizes or a printable template, enter the dimensions in the calculator above.
| Main pipe | Branch pipe | Circumference | Depth 90° | Depth 60° | Depth 45° |
|---|---|---|---|---|---|
| NPS 1" (1.315 in) | NPS 1/2" (0.840 in) | 2.639 in · 67.0 mm | 0.152 in · 3.9 mm | 0.496 in · 12.6 mm | 0.840 in · 21.3 mm |
| NPS 1" (1.315 in) | NPS 3/4" (1.050 in) | 3.299 in · 83.8 mm | 0.262 in · 6.6 mm | 0.666 in · 16.9 mm | 1.059 in · 26.9 mm |
| NPS 1 1/4" (1.660 in) | NPS 1" (1.315 in) | 4.131 in · 104.9 mm | 0.323 in · 8.2 mm | 0.831 in · 21.1 mm | 1.325 in · 33.6 mm |
| NPS 1 1/4" (1.660 in) | NPS 1 1/4" (1.660 in) | 5.215 in · 132.5 mm | 0.830 in · 21.1 mm | 1.438 in · 36.5 mm | 2.004 in · 50.9 mm |
| NPS 1 1/2" (1.900 in) | NPS 1" (1.315 in) | 4.131 in · 104.9 mm | 0.264 in · 6.7 mm | 0.791 in · 20.1 mm | 1.315 in · 33.4 mm |
| NPS 1 1/2" (1.900 in) | NPS 1 1/4" (1.660 in) | 5.215 in · 132.5 mm | 0.488 in · 12.4 mm | 1.114 in · 28.3 mm | 1.711 in · 43.5 mm |
| NPS 1 1/2" (1.900 in) | NPS 1 1/2" (1.900 in) | 5.969 in · 151.6 mm | 0.950 in · 24.1 mm | 1.645 in · 41.8 mm | 2.294 in · 58.3 mm |
| NPS 2" (2.375 in) | NPS 1 1/2" (1.900 in) | 5.969 in · 151.6 mm | 0.475 in · 12.1 mm | 1.207 in · 30.7 mm | 1.917 in · 48.7 mm |
| NPS 2" (2.375 in) | NPS 2" (2.375 in) | 7.461 in · 189.5 mm | 1.188 in · 30.2 mm | 2.057 in · 52.2 mm | 2.867 in · 72.8 mm |
Common mistakes with saddle cuts
- Wrong print scale: "Fit to page" shrinks the template by a few percent – always measure the ruler.
- Scribing the inside line: scribe the gold outer contour; the blue inner contour only shows how far to finish on the inside.
- Forgetting the wall thickness: on thick walls the outer and inner contour are far apart. Cutting only on the outside leaves material in the way on the inside.
- Template turned round: on angled joints the saddle is not symmetric – scribed 180° out, it ends up on the wrong side. Hold the pipe against the main pipe before cutting.
- Nominal size instead of outside diameter: the calculation uses the outside diameter – NPS 1-1/4" is 1.660 in. The standard pipe list in the calculator helps.
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.
What is an offset branch?
The branch pipe does not sit on the center line of the main pipe but is shifted sideways – for example flush with the outside, as on many railings and frames. Enter the offset under "More options" or tap "Flush"; the template, the 3D view, the DXF and the CSV all include the offset. A negative value shifts the branch to the other side.
Which hole saw do I need for a tube notcher?
A hole saw with the outside diameter of the main pipe, for example 1.900 in for 1-1/2" pipe. A smaller saw cuts too tight, a larger one leaves a gap. If you want a weld gap, the saw is larger by twice the gap. Below the flat pattern the calculator shows hole saw, swing angle and offset for your input.
Do I also need a hole in the main pipe?
Usually not for railings – the branch is set on and welded. If fluid or air has to flow through, or if the branch is set through the main pipe, the main pipe needs an opening. The calculator can print a second template that is wrapped around the main pipe: gold for a set-through branch, blue for a set-on branch.