Retractable Pocket Saw - 3D Printed - EDC

Having a small saw to carry in your pack, tool pouch, car, or pocket allows you to make quick cuts as needed, when on the move without carrying bulky tools. This saw falls into the Every Day Carry (EDC) realm. It's not meant to be heavy duty, but versatile and available for small jobs and emergencies.

It is a 3D printed handle and retracting slide and can be customized by selecting a variety of commercial blades to be incorporated during the assembly. It uses a T shank jig saw blade that is 3 inches long. Selection of the number of teeth per inch on the blades adapts it for various uses. Multiple saws can be made because they are small and inexpensive.

3D Printer

3D Material

Commercially available T shank jigsaw blade (3 inch)

Examples:

DEWALT - DW3776-5

Bosch T102H

Milwaukee 48-42-5190 3 in. 14 TPI

Glue (super glue - cyanoacrylate)

I used CAD to design the saw. It took a bit of adjustment after printing the first prototype to get the retraction to work smoothy.

A CAD model of the T Shank of the blade was created to use as a design reference. By using glue to assemble the saw it eliminated the space required to design in screw bosses or snaps and saved significant room. The goal for this design was to make it small, but to do that a trade off was to make assembly permanent.

Incorporating the latching mechanism into the handle and blade holder design saves both space and complexity.

Two protrusions from the handle prevent your hand from sliding onto the blade.

Parts needed:

T Shank 3 inch jigsaw blade

Bottom Hande

Top Handle

Blade Holder - Top

Blade Holder - Bottom

Most 3D printers will print this easily. I used a small Flashforge printer and PLA material for this initial work. Tougher materials such as PETG or Nylon could be used to achieve additional durability.

The Handles and Blade Holder - Bottom can be printed without supports.

The Blade Holder - Top's design requires supports to allow printing.

The Blade Holder was printed in a contrasting red color to allow for better visibility.

I printed with PLA material at 0.1 mm layer height (first layer was set to .3 mm)

The Blade Holder - Top was printed on its side (as shown in the pictures) and supports added along one edge which were removed with a knife.

Prior to final assembly a test fit of parts is recommended. Depending on your printer, mterial and settings some variations in parts can be expected. This saw is designed with minimal clearances, and some adjustments may be needed for your build. Minor adjustments can be made with sandpaper.

To test fit, some assembly is required. Glue the blade to the Blade Holder - Bottom. Glue the top Blade Holder on, aligning the edges to the bottom. Clamp the assembly for a short period to assure adhesion.

Test fit again with the blade into the handles. If everything fits properly, then reassemble the top and lower handle with glue and let it dry. Using a toothpick to transfer the glue to the inside of the lower handle makes it easier to control the glue placement.

NOTE: Take care not to let the glue run down onto the area the blade and blade holder slide to prevent any sticky or frozen motion.

The result is a handy little saw just over 3 inches long. Very easy to carry. Enjoy!