Hacksaw

Hacksaw

Every year, the Cal Poly Machine Shops hosts a secret santa gift exchange, where you have to make a Christmas gift. For 2024, I designed and fabricated my own hacksaw design. I liked the design so much; I ended up making three hacksaws in total.

For this hacksaw I wanted a clean aesthetic with only simple lines and curves. The hacksaw frame was cut on a waterjet, drilled, tapped, and then powder coated. The handles were then 3D printed on a Markforged 3D printer using a carbon fiber nylon filament.


Finished Hacksaws

Hacksaw for my secret santa

Hacksaw for my dad

Hacksaw for myself

Design/Manufacturing Process

Hacksaw frame sketching ideation

Finalized hacksaw design sketch

CADed hacksaw frame

Laser cut a prototype hacksaw to verify its function

Waterjetting finalized hacksaw design

Powder coating hacksaw frame

Hacksaw Manufacturing Time Lapse