Portable Dual-Blade Panel Saw Design

PROJECT TITLE Portable Dual-Blade Manual Panel Saw (Hand-Cutter Based Design) OBJECTIVE Design a compact, portable woodworking cutting machine based on a handheld cutter platform that can perform chip-free cutting of laminated boards using a dual-blade system (main blade + scoring blade). The machine must be suitable for small workshops and on-site use, with high accuracy and ease of handling. CORE FUNCTIONAL REQUIREMENTS 1. Dual Blade System • The machine must include a main cutting blade (≈180 mm) and a scoring blade (70–90 mm). • Both blades must be aligned on the same cutting axis (same line of cut). • The scoring blade must be positioned 30–40 mm ahead of the main blade. • The scoring blade must rotate in the opposite direction to the main blade. 2. Independent Motor System • Separate motors for each blade. • Main motor: 1200–1800 W • Scoring motor: 300–500 W high RPM • Proper motor mounting with vibration isolation. 3. Adjustment Mechanisms The design must include precise and user-friendly adjustments: • Main blade depth adjustment: 0–60 mm • Scoring blade depth adjustment: 0–3 mm (fine control) • Sideways micro-adjustment for scoring blade alignment (±1 mm tolerance) • Blade tilt mechanism: 0°–45° bevel cutting capability • All adjustments must have locking mechanisms for stability. 4. Base and Movement System • Flat base plate: approx. 320 × 220 mm • Four or more roller supports with bearings for smooth movement over panels • Rollers must reduce friction and maintain straight cutting motion • Base must remain stable without wobble. 5. Handheld Cutter Design • Overall design should resemble a professional handheld circular saw • Include two ergonomic handles for two-hand operation • Balanced weight distribution for operator control • Compact and portable structure. 6. Structural Design (3D Printable + Metal Hybrid) • Body must be designed as modular components for prototyping • Suitable for 3D printing (PETG/ABS/nylon) with reinforcement • Include provisions for: – metal inserts for strength – bearing seats – motor mounts • High rigidity to maintain blade alignment under load. 7. Width Gauge System • Removable adjustable side fence (0–300 mm range) • Must allow accurate straight cutting along board edges • Include measurement scale and locking mechanism. 8. Safety Features • Blade guards for both blades • Transparent safety shield • Emergency stop switch • Dust extraction port (35 mm or compatible) • Electrical insulation and safe wiring paths. 9. Accuracy Requirements • Cutting tolerance target: ±0.5 mm • Scoring alignment precision: ±0.2 mm • Smooth, chip-free laminate cutting. 10. Assembly and Manufacturing • Design must include: – bolt connections – alignment pins – easy assembly/disassembly • All parts must be manufacturable via: – CNC (for metal parts) – 3D printing (for housing components) DELIVERABLES FROM DESIGNER • Complete 2D engineering drawings (top, side, front views) • 3D CAD model (STEP/STL files) • Exploded view with part list • Assembly instructions • Material specifications • Tolerance and fit details • Motor and bearing selection recommendations DESIGN GOAL The final product should be a compact, affordable, and professional-grade portable panel saw that combines: • accuracy of panel saw • portability of hand cutter • clean cutting with scoring blade The design should be suitable for real-world fabrication and commercialization.

Project ID: 40350530