Description
The Lew Electric 3.5-inch round pop-up outlet template provides countertop fabricators with an essential CAD tool for creating precise circular cutouts for Lew Electric's PUR series round retractable power outlets. This compact round design offers an elegant solution for integrating power and USB charging into kitchen islands, peninsula counters, office desks, and conference tables without compromising the clean aesthetic of premium stone and solid surface installations. The template specifies a 3.75-inch diameter circular cutout that accommodates the PUR series mounting flange while ensuring smooth pop-up operation and a flush bezel fit when closed. Round pop-up outlets have become increasingly popular in modern kitchen and office design due to their minimal visual footprint and versatile placement options—they can be positioned in tight spaces, corners, or areas where rectangular outlets won't fit. This DXF template eliminates guesswork and measurement errors, providing fabricators with a ready-to-use cutting path that integrates seamlessly with CNC routers and waterjet cutting systems. Whether you're fabricating high-end residential kitchens, commercial office environments, or hospitality installations, this template ensures consistent, professional results that meet both functional requirements and aesthetic expectations.
Related Templates
The Lew Electric 3.5-inch round pop-up outlet template provides countertop fabricators with an essential CAD tool for creating precise circular cutouts for Lew Electric's PUR series round retractable power outlets. This compact round design offers an elegant solution for integrating power and USB charging into kitchen islands, peninsula counters, office desks, and conference tables without compromising the clean aesthetic of premium stone and solid surface installations. The template specifies a 3.75-inch diameter circular cutout that accommodates the PUR series mounting flange while ensuring smooth pop-up operation and a flush bezel fit when closed. Round pop-up outlets have become increasingly popular in modern kitchen and office design due to their minimal visual footprint and versatile placement options—they can be positioned in tight spaces, corners, or areas where rectangular outlets won't fit. This DXF template eliminates guesswork and measurement errors, providing fabricators with a ready-to-use cutting path that integrates seamlessly with CNC routers and waterjet cutting systems. Whether you're fabricating high-end residential kitchens, commercial office environments, or hospitality installations, this template ensures consistent, professional results that meet both functional requirements and aesthetic expectations.
Installation Overview
Installing a Lew Electric 3.5-inch round pop-up outlet requires careful planning, accurate cutting, and attention to clearance requirements beneath the countertop surface. The installation process begins with positioning the template at the desired location, taking into account the unit's operational requirements and maintaining minimum edge distances from countertop perimeters—typically at least 2 inches from any edge to prevent structural weakness and cracking. The template defines a 3.75-inch (3 3/4-inch) diameter circular cutout, which is the standard opening for Lew Electric PUR series round pop-up outlets. This cutout must be executed with high precision to ensure the threaded mounting flange engages properly from beneath the countertop and the bezel sits flush with the finished surface. Before cutting, verify that adequate clearance exists beneath the countertop—the PUR series requires approximately 5-6 inches of vertical space below the surface to accommodate the retracted pop-up mechanism, electrical connections, and the power cord. The mounting surface thickness must be between 3/8 inch and 2 3/16 inches to ensure proper engagement of the mounting hardware. When positioning the cutout, consider the direction in which the pop-up extends when activated; although the mechanism rises vertically, you should avoid placement directly beneath overhead cabinets or against backsplashes that might interfere with operation or access to the outlets. For installations in natural stone materials like granite or marble, inspect the slab carefully for veining patterns, fissures, or mineral inclusions that could compromise the circular cutout area. The round geometry distributes stress evenly, making it one of the most structurally sound cutout shapes for stone materials, but intersecting fissures can still create weak points. Test-fit the pop-up unit after cutting to confirm proper alignment, smooth operation of the pop-up mechanism, and adequate clearance for all electrical components before final installation and wiring.
CNC Cutting Notes
CNC fabrication of the 3.5-inch round pop-up outlet cutout requires careful programming and appropriate tooling to achieve clean, accurate circular openings across different countertop materials. The circular geometry offers some advantages over rectangular cutouts—there are no corners to manage, and stress is distributed evenly around the perimeter, reducing the risk of cracking. Begin by importing the DXF template into your CAM software and verifying that the circle diameter measures exactly 3.75 inches in your CNC coordinate system. For cutting granite, engineered quartz, and other hard stone materials, select diamond-coated router bits appropriate for circular interpolation; a 1/4-inch or 3/8-inch diameter bit works well for most applications. Program your toolpath using circular interpolation (G02/G03 arc moves) rather than approximating the circle with linear segments, which can create faceted edges and dimensional inaccuracies. Use multiple depth passes with Z-axis increments of 3-5mm per pass to reduce cutting forces and minimize tool wear. Implement helical or ramping entry strategies to ease into the material rather than plunging straight down, which can cause surface chipping and excessive tool stress. Maintain continuous water cooling directed at the cutting interface to manage heat generation and flush away cutting debris. The circular toolpath allows for consistent feed rates throughout the cut, which helps achieve uniform edge quality and finish. For engineered quartz materials, monitor cutting temperatures carefully as the resin binder can be damaged by excessive heat, potentially causing discoloration or weakening around the cut edge. Solid surface materials like Corian cut easily with carbide tooling and can tolerate higher feed rates, making them economical to process. When programming for ultra-compact surfaces like Dekton or Neolith, reduce feed rates significantly and use specialized diamond tooling designed for extreme hardness materials. Ensure proper material support beneath the cutout area using your CNC table support system—the circular plug will become free-floating as the cut completes, so having adequate support prevents the plug from dropping and potentially damaging the finished surface or breaking away prematurely, which could chip the cutout edge. Some fabricators prefer to leave small tabs (0.5-1mm) that hold the circular plug in place during cutting, then carefully remove these tabs with hand tools after the CNC cycle completes.
Material Compatibility
The 3.5-inch round pop-up outlet template offers excellent compatibility with all standard countertop materials used in residential and commercial fabrication. The circular geometry is particularly well-suited for natural stone materials including granite, marble, and quartzite because the round shape distributes stress evenly with no corner stress concentrations that can initiate cracks. When cutting granite, the round cutout minimizes the risk of following natural fissure planes or weak areas in the stone structure. Engineered quartz materials from manufacturers like Caesarstone, Silestone, Cambria, and others are ideal candidates for round pop-up installations due to their consistent composition, uniform strength properties, and predictable cutting behavior. The compact 3.75-inch diameter creates a relatively small opening that maintains structural integrity even in thinner 2cm quartz slabs. Solid surface materials including Corian, Hi-Macs, and Wilsonart solid surfaces provide the most forgiving fabrication experience—these thermoformable materials can be cut easily, and the mounting holes can be drilled precisely to accommodate the pop-up's threaded mounting flange. Ultra-compact surfaces like Dekton, Neolith, and Lapitec require specialized tooling but deliver exceptional durability for high-traffic commercial applications; the round cutout geometry helps minimize edge chipping that can occur with these ultra-hard materials. Marble and limestone installations benefit from the round geometry's stress distribution, though extra care should be taken with softer stones to prevent edge breakage during cutting and installation. Wood butcher block countertops accommodate round pop-up outlets successfully when grain orientation is considered—ideally position the cutout to avoid alignment with end grain sections that might have less structural integrity. Concrete countertops can integrate round pop-up outlets effectively, especially when steel reinforcement mesh or rebar is placed during casting to support the area around the cutout. Laminate countertops, though less common for premium pop-up outlet installations, can be cut successfully using sharp carbide tooling with backing support to prevent delamination. Always consult material manufacturer specifications for recommended edge distances, support requirements, and any special considerations when cutting openings in their products.
Where to Buy
Lew Electric round pop-up outlets in the PUR series are available through electrical distributors, countertop fabrication suppliers, kitchen and bath showrooms, and online retailers serving the construction and remodeling industries. Major electrical supply houses including Graybar, Rexel, CED Greentech, and regional electrical distributors typically stock or can quickly order Lew Electric products. Countertop fabrication suppliers often carry these items as complementary products to their stone, quartz, and solid surface offerings. For direct purchase, online retailers including Amazon, Kitchen Power Pop Ups (kitchenpowerpopups.com), Floor Box Outlet (floorboxoutlet.com), and Pop Up Outlets (popupoutlets.com) offer extensive selections of Lew Electric PUR series units in multiple finish options. The PUR series is available in seven finish choices including black metal, black tempered glass, brass metal, dark bronze metal, nickel silver metal, stainless steel metal, and white metal, allowing coordination with various kitchen and office design aesthetics. When ordering, specify the exact model number and outlet configuration—PUR series units are available with GFCI protection (PUR20GD models), standard duplex receptacles (PUR20DSD models), or combination power and USB charging configurations (PUR20ACD models with USB-A and USB-C ports). The most popular configurations include the PUR20GD series with integrated GFCI protection for code-compliant countertop installations, and the PUR20ACD series featuring both AC power and fast-charging USB ports. For commercial projects or volume orders, consider establishing direct relationships with Lew Electric authorized distributors who can provide competitive pricing, technical support, and product availability information. Lead times vary by finish and configuration but typically range from immediate stock availability for popular models like stainless steel GFCI units to 1-3 weeks for specialty finishes or less common configurations. When specifying units for client projects, note that some finishes command premium pricing over standard options—tempered glass tops and specialty metal finishes typically cost more than basic white or stainless steel. Always verify current product specifications, cutout dimensions, and clearance requirements from the manufacturer's most recent installation documentation before cutting countertops, as product designs and requirements may be updated.