New Jigsaw Design

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Forum topic by JeffStarr posted 05-09-2009 12:54 AM 2402 views 0 times favorited 12 replies Add to Favorites Watch
View JeffStarr's profile


90 posts in 4412 days

05-09-2009 12:54 AM

Topic tags/keywords: jigsaw power tool

My fellow Lumberjocks,

I am an Industrial Design major at Arizona State University. I am finishing up my final project and wanted to post it here for some feedback I could use in my final presentation. My assignment was to redesign the jigsaw power tool. I have posted the finished 3-D model I made in solidworks and rendered life like on my computer. I would appreciate your feedback (likes, dislikes, other potential features) on the changes I have made from the traditional jigsaw. Since designing this I have found that Festools and a couple of other companies have also designed the jigsaw without the D-Handle I guess I wasnt the first to think of it but it is nice to know it was a good idea. Also if you have any questions please let me know. Thanks for your help. Jigsaw Redesign

-- "When was the last time you did something special for your gun?"

12 replies so far

View DaleM's profile


958 posts in 4460 days

#1 posted 05-09-2009 01:11 AM

Is there a way to defeat the kill switch, for instance if you wanted to just remove a thin slice of wood from the edge of a board and it would be easier to cut with side of the saw opposite the kill switch resting on the wood. If the width of wood you wanted to remove was less than the distance from the blade to the switch, the saw wouldn’t work would it? I don’t see any problems other than that.

-- Dale Manning, Carthage, NY

View JeffStarr's profile


90 posts in 4412 days

#2 posted 05-09-2009 01:14 AM

Good comment, I figure I could easily install manual override switch. And while it is on override the red lights could be off indicating that you are on override. Thanks for the suggestion.

-- "When was the last time you did something special for your gun?"

View lew's profile


13353 posts in 4832 days

#3 posted 05-09-2009 01:54 AM

Is that the On/Off switch on the side? Is there one on the opposite as well- for left handed people?

The offset is great for the right handed persons’ visibility, maybe not so great for left handed people.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View JeffStarr's profile


90 posts in 4412 days

#4 posted 05-09-2009 02:07 AM

Yes its actually a double trigger, with one on each side. My intention was that you would depress one or the other or even both, a button that you would hold down rather than switch on. That way it could be used with either hand but unfortunately for some was targeted for right handed use. But occasionally you may need to use it with the left on an awkward cut. If this offset was popular enough it could be manufactured offset to the left for left handed people based on the demand. Thanks for the comments.

-- "When was the last time you did something special for your gun?"

View Gary's profile


9419 posts in 4509 days

#5 posted 05-09-2009 02:09 AM

Can’t tell, did you incorporate a blow tube from the motor to blow the saw dust away from the line? Also, it appears to be a quick release, is that correct?

-- Gary, DeKalb Texas only 4 miles from the mill

View mtnwild's profile


4047 posts in 4604 days

#6 posted 05-09-2009 02:10 AM

I once had to rip a sheet of nice oak plywood into 6” strips, length wise. Yes 8’. I did not want to chip the nice part and not having the best of tools my best choice turned out to be a Japanese pull saw. I cut all the cuts just perfect. Did not take as long as you might think. .............Anyway, what about angling the blade, variable speed. Maybe even a forward pull attachment. Good designed blade, like those fine cut pull saws. Just an idea, good luck….....Jack….........

-- mtnwild (Jack), It's not what you see, it's how you see it.

View miles125's profile


2180 posts in 5082 days

#7 posted 05-09-2009 02:12 AM

I’m a fan of the D handle. Theres great advantage to having the weight of your hand nearly directly over the blade. Especially when you want to stop a cut and make sure you dont incidentally move and cut more as the blade idles to a stop. Just something i’ve noticed.

-- "The way to make a small fortune in woodworking- start with a large one"

View JeffStarr's profile


90 posts in 4412 days

#8 posted 05-09-2009 02:21 AM

Gary, the blow tube is at the bottom of the tool where it attaches to the base plate. I did not draw in the vacuum hose and therefore it isn’t to obvious on the images I provided here. I will remedy that for my presentation.

mtnwild, I am not familiar with a Japanese pull saw, I will look into that. I will also need to add a view with the tool on an angle to illustrate that ability.

miles125, I appreciate the insite on the D-Handle. Your comment about being able to stop precisely is definitely a valid argument for the D-Handle.

Thanks for the ideas.

-- "When was the last time you did something special for your gun?"

View brunob's profile


2277 posts in 5246 days

#9 posted 05-09-2009 02:32 AM

What about a detachable “D” handle?

-- Bruce from Central New, if you'll pardon me, I have some sawdust to make.

View daltxguy's profile


1373 posts in 4990 days

#10 posted 05-09-2009 03:00 AM

I’m not a fan of the D-handle and the idea of not having one is certainly not new. I am the owner of a Bosch 1584vs, which I really like. What I like about it is the low center of gravity, therfore better control. I also like the doorknob handle over the blade which I can hold for extra control as a pivot point. It also doubles as part of the ‘click’ quick blade change design ( turn counterclockwise to loosen the blade – clockwise until it clicks to tighten the blade). Even though that’s a copy, you may want to consider adding something like that since I really like it.

Your ergonomic handle is a nice improvement, though.

I’d like a nice, large, flat sole plate, not the stamped steel that most jigsaws come with. I realize yours is rendered but if you rendered it to look like anodized aluminum, I would be more inclined to think it was a quality sole plate than a chromed piece of stamped steel.

On the 1584vs, the switch is not all that conveniently located. It is near my thumb, but I have to stop, hold the saw and reach for the switch when I go to turn it off. Yours looks to be in the same location as the Bosch. Also, I imagine it is more diffucult to use for lefties if placed on the side.
How about a switch that activates with the squeeze of the hand around the handle, rather than a finger trigger? or this is a safety problem?

-- If you can't joint it, bead it!

View Canexican's profile


108 posts in 4754 days

#11 posted 05-09-2009 05:48 AM

I think your design looks great, nice rendering Jeff. What about cordless… I would love to have tools that can go from cordless to corded when needed. Also how about having a place for blade or tool storage. I hope that every adjustment is toolless, I hate having all these little specialized wrenches around for all my tools. Is the handle rubberized for comfort and vibration reduction, and maybe move the lights to the top of the machine so they are easily viewed from either side. Best of Luck on this Project….


View JeffStarr's profile


90 posts in 4412 days

#12 posted 05-09-2009 08:06 AM

Thanks for the feedback. I wish I would have known about lumberjocks when I first began designing this tool as a couple of months ago, the suggestions are very valid in that they are based completely off of your years of experience. This feedback is very beneficial to me.

brunob – I will have to look into the detachable handle. The main issue I see with that would be the dissconecting of the trigger wiring on the D-handle.

daltxguy – I dont know that a hand trigger would be a safety issue as long as you carry the tool in a different position than you operate it. My triggers were meant to be squeeze triggers, one on each side. I know my images do not show the other side, my bad.

Canexican – I have added some gell type padding onto the handle, thanks to your suggestion. I am still deciding on a good home for the LEDs, the top was meant for your other hand if you chose to use both hands and therefore would cover them completely.

-- "When was the last time you did something special for your gun?"

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