Automated Table Saw Cuts Photovoltaic Solar Cells

[sudarshan] is a solar hobbyist and needed a way to cut solar cells for his projects. He had previously created a rotary tool saw but manually feeding them through was sketchy at best. With just a slight wrong movement of his hand or flex in the work surface would cause the cell to break. These cells are extremely brittle and break easily. He needed a method of cutting these cells that was free from jitters and would cut in a straight line. He looked around his junk bin and found an odd solution… a scanner. Yes, the type you would scan photos in your computer with. The scanner had two critically important features, a flat surface and a carriage mechanism that moves perfectly parallel with that flat surface.

[sudarshan] made a solar cell cutting mini table saw with that scanner and made the cutting happen automatically. He mounted a motor with a diamond saw disk to the carriage, that is responsible for the cutting. The blade was positioned just high enough to poke through the plexiglass that replaced the original glass bed. A power switch turns on the cutting disk motor and an Arduino was used to move the carriage, including the cutting blade, back and forth. Two of the stock scanner buttons were reused and wired to the Arduino to keep the saw looking good.

The first few passes of the saw were done to cut a slot in the plexiglass. In order to cut a solar cell, the cell is taped to the bed with the desired cut location aligned with the slot in the plexiglass bed. Once everything is set, hit the ‘go’ button and the saw blade is slowly pushed through the cell, leaving a straight, clean cut.

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DIY Super Accessory For Your Dremel

Little jobs require little tools and you can’t get much more littler than a Dremel. For his tiny tasks, [sdudley] has built a Dremel-powered base station that features a table saw, drum sander and router table. Overall, it is about one cubic foot in size and is almost entirely made from ‘1 by’ dimensional lumber. The Dremel power plant was actually used to make the base, specifically slowly removing material at the clamping points that hold the rotary tool secure to the base. The Dremel is held in an upright position and pokes out through the center of the table for both the drum sander and router configurations. To use this as a table saw, the Dremel is mounted almost horizontally on the base. A Mini Saw attachment has to be purchased for the table saw configuration but it does a great job at holding a vertically spinning saw blade.

After the break there’s a nice video of this tool’s use and assembly (it’s even worth watching just for the musical accompaniment that takes you on a wild ride through several genres of music). For those who want to make one for themselves, [sdudley] has made his part templates and assembly guide available in PDF format on his Instructables page. If you’re looking for something a little larger, check out this circular saw converted to a table saw.

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Table Saw Kickback Video Ends Badly

Our comments section has been pretty busy lately with talk of table saws and safety, so we decided to feature this sobering video about table saw kickback. [Tom] is a popular YouTube woodworker. He decided to do a safety video by demonstrating table saw kickback. If you haven’t guessed, [Tom] is an idiot – and he’ll tell you that himself before the video is over. There are two hacks here. One is [Tom’s] careful analysis and preparation for demonstrating kickback (which should be fail of the week fodder). The other “hack” here is the one that came breathtakingly close to happening – [Tom’s] fingers.

Kickback is one of the most common table saw accidents. The type of kickback [Tom] was attempting to demonstrate is when a board turns and catches the blade past the axle. On a table saw kickback is extremely dangerous for two reasons. First, the piece of wood being cut becomes a missile launched right back at the saw operator. We’ve seen internal injuries caused by people being hit by pieces of wood like this. Second, the saw operator’s hand, which had just been pushing the wood, is now free to slid right into the blade. This is where a SawStop style system, while expensive, can save the day.

The average 10 inch table saw blade has an edge traveling at around 103 mph, or 166 kmh. As [Tom] demonstrates in his video, it’s just not possible for a person to react fast enough to avoid injury. Please, both personal users and hackerspaces, understand general safety with all the tools you’re using, and use proper safety equipment. As for [Tom], he’s learned his lesson, and is now using a SawStop Table.

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Circular Saw to Table Saw Conversion

Corded circular saws are a dime-a-dozen at any old thrift store, yet table saws are a bit more of a costly investment — have you ever wondered if you could just make one out of a circular saw? [Matthias Wandel] did, and he just so happens to be very good at woodworking! He makes a lot of great woodworking videos to share on YouTube, and in his latest blog post, he shows us a rather elaborate way to convert a plain old circular saw, into a functional table saw.

While the concept seems simple, unless you do a lot of woodworking, you’ll probably marvel at how easily making things comes to [Matthias] — we know we did. By the end of the video he has a fully functional table saw that can raise and lower in height, and cut at different angles.

If you’re interested in making one yourself, he does a very thorough job explaining the process in his video — check it out after the break!

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A tiny custom table saw

saw

If you’re working with small parts, even the smallest table saw available at Home Depot or Lowes is generally overkill. For cutting up small pieces of wood, metal, and copper-clad board, a micro table saw is a great investment. They’re actually pretty inexpensive, but why just buy one when you can make one that is better than any model on the market?

The bed is constructed out of 1/4″ aluminum plate with a 1/15 horsepower motor bolted to the underside. The fence clamps on to the table with a pair of delrin brackets, while the angle guide is made of delrin and a brass bar that fits into a slot in the table.

The actual blades came from a Proxxon micro table saw (a very good brand from our experience), but comparing this homemade saw to the commercial one provides a few surprises: The Proxxon has a more powerful motor, but the homebrew version has four times the cutting capacity. You can check out this saw cutting a 1/4″ aluminum bar in the video after the break.

Thanks [Hubert] for sending this one in.

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Rusty old table saw turned into a workstation worthy of a master craftsman

rusty-old-table-saw-turned-pro-workstation

Okay, first of all: holy crap! Even if you didn’t know this started as a rusty table saw, the workstation that came out of this project is just phenomenal. It really makes us wish we had looked around for a used model with a cast iron top instead of going for the cheap stamped metal one that was ready to use.

[Simon Leblanc] started with a Delta contractor’s saw that was rusty inside and out. The refurbishment began by removing the table and everything from the inside. The rods and gears were all cleaned up before he began to sand away the rust on the table itself. But obviously he didn’t stop with getting the saw to be functional again. He built a small set of cabinets to serve as the base for the saw. They went inside of this larger assembly that combines an MDF table top with an Accusquare rip fence to greatly increase the working surface of the tool.

Now he needs to start in on an extra fancy CNC jig for the thing.

[via Reddit]

CNC Table Saw Jig

table saw jig

[Woodgears.ca] seems to be a wealth of clever hacks, and this CNC box joint jig is no exception.  Although one has to manually move the jig to make the actual cut, it still gives the user a lot of extra functionality. One only has to click the mouse button to advance the workpiece.  One drawback to using a table saw, even with this jig is that some internal parts still may have to be cut. Check out the video after the break to see this device in action, or skip to around 3:08 to see what hand operations still have to be done.

Besides just being a cool build, we loved the box-jointed project enclosure for the electronics. As this was made in 2003, it’s nice to see that the idea of “self-replication” (at least in part) didn’t start with the [Rep-Rap]. The 10 year old (as of 2003) Thinkpad notebook computer running QBasic in DOS is a nice “hacker” touch as is using 100 Watt light bulbs as power resistors. Pretty clever electronics, especially for someone that’s known more for his excellent woodworking skills than his obvious electrical engineering knowledge! Continue reading “CNC Table Saw Jig”