PROJECT BRIEF

The project originated by D. Poole as an effort to rethink the conventional pocket-hole jig platform by introducing automatic adjustment for material thickness. Early exploration drew inspiration from prior self-adjusting systems, including the Porter-Cable ramp-style drill guide, while seeking a more integrated and manufacturable solution.

The patented double spur-gear mechanism was ideated by Mike to synchronize adjustment of the drill guide block and drill-bit collar, automatically setting drilling geometry based on material thickness. He led concept development, CAD engineering, and integration of the mechanism within the auto-adjusting pocket-hole jig platform, refining the system through multiple prototype iterations produced and tested in-house at PDI, and later directing mid-stage refinements and prototype work carried out at TTI. Functional assemblies were also stress- and cycle-tested and approved by PDI founders R. Poole and D. Poole.

Final-stage geartrain refinement, drilling confirmation studies, clamping mechanism integration, ergonomic refinement, on-site manufacturing setup, QA, batch-sample cycle testing, and packaging and user-manual artwork and copy, renderings+animations were completed by Mike.

ARMOR TOOL™ AUTO-JIG™

The Armor Tool Auto-Jig is an award-winning pocket hole system recognized by the Pro Tool Innovation Awards (PTIA) and the National Hardware Show Retailers Choice Awards. It is designed to deliver fast, accurate pocket holes with almost no setup. Its fully self-adjusting mechanism sets the drill guide and collar depth to match your material thickness the moment you clamp the board. This eliminates manual measurements and makes consistent results simple for both new users and the experienced. Color-Coat, all-weather screws and the matching color chart remove guesswork when selecting the right fastener for any board thickness.

The Auto-Jig was developed with late-stage cooperation from Techtronic Industries and was the first pocket hole jig to introduce true self-adjusting technology. It remains the only system that automatically adjusts both the drill guide position and the drill collar depth in a single movement. Its simple, reliable auto-setup inspired competing designs in the category and helped redefine expectations for pocket hole jigs.

The Auto-Jig is built for accuracy, durability, and a smooth workflow that keeps you focused on the project rather than the setup. The system’s award-winning design and broad industry recognition reflect its role in bringing true automatic adjustment to mainstream woodworking.

Product Visualization Animation (AETOR)

Selection of sketches: 1) the original ideation of the drill-collar auto-adjustment, 2) early modification of the locking mechanism that later evolved into the ratcheting clamping-force adjustment screw, and 3) a revised drill-hole spacing concept developed to avoid potential IP conflicts.

Selection of early 3/4 isometric form studies exploring the overall industrial design direction of the bench-top Auto-Jig. These sketches focus on proportion, visual architecture, and user interaction, including early concepts for the vacuum attachment and handle ergonomics as the platform took shape.

Development progression of the Auto-Jig, showing selected milestones from a broader iteration process -- beginning with one of the earliest functional prototypes and progressing to later-stage iteration, the painted and labeled presentation prototype used for the private preview at IWF Atlanta 2018, first article from tooling, and production article from pilot batch.