January - April 2026

Duration: 15 weeks

Project Description: Redesign an existing handheld

power tool and uncover problems and complaints to

discover how to improve the chosen tool

Discover

Discover

Immersion Experience


Before settling on a circular saw as my tool, a few peers and I interviewed a woodworking hobbyist with decades of experience. We gathered information about dozens of different handheld power tools, and there were a few key takeaways we had after our interview. Our woodworker, Dennis, consistently addressed safety as the number one priority in power tool advancement. He followed that up with the importance of innovation, citing tools such as the Domino joiner as the reason why modern woodworking hobbyists can create professional-level furniture. The final insight from our conversation came from Dennis touching on different power tool manufacturers, and how he chooses the best ones for his needs.

Click to view Task Analysis

Click to view circular saw Benchmarking

Inspiration Boards

Sketches

Round Two Focuses


  • handle form

  • blade-lowering mechanism

  • battery placement

  • body form

  • additional features

CAD

Surfacing


Models were formed around internal components to ensure realistic proportions and sizing

Foam Models

handles with

maximized ergonomic

features, built into

later models

Design Pivot & Branding Decision:

In order to create the most impactful design possible and truly solve the issue

of safety, I decided to incorporate the SawStop safety feature in my saw. This

required a deep understanding of the mechanism itself, as well as the math

and physics behind creating my own version of it.

Necessary Components for SawStop Mechanism

Blade

Cartridge

Motor

Induction Brake

Mechanism

Battery

CAd Progression

CAd Progression

Final Renders

Final Poster