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.