Making An Air-Powered Circular Saw With LEGO

September 12, 2026 by Maya Posch 9 Comments

The all-LEGO version barely cuts paper. (Credit: Jamie's Brick Jams, YouTube) — The all-LEGO version barely cuts paper. (Credit: Jamie’s Brick Jams, YouTube)

Although building a table saw out of LEGO is probably not the first thing that comes to mind when you look at those colorful bits of plastic, [Jamie] has been on a bit of a search for more applications of his LEGO-based air-powered motors. Naturally this led to the idea of doing something useful with it, like making a table saw you can actually use for real wood.

Starting off with a basic prototype using only regular LEGO pieces to get the mechanism figured out, [Jamie] then builds this up into said air-powered table saw featuring an actual metal blade. Suffice it to say that this isn’t something that you want your children to do with their LEGO while unsupervised.

The star of the show is of course the air-powered turbine that spins the blade. This is something that [Jamie] has been working on for a while, going through a number of prototypes to figure out a 3D printed geometry for the turbine blade that helps to convert as much of the high-pressure air into rotation.

Along the way it was also discovered that 3D printing saw blades is pretty hard, probably due to the lack of a sharp edge. This is definitely an area where it’s hard to beat a real table saw blade, with the added caveat that anything that’s good at cutting up boards of wood and sausages will just as happy slice through careless primate fingers.

In terms of safety features, the air supply is cut automatically with a sort of dead-man switch that requires you to keep one hand on it while using the final table saw design. There also an auto-feeding system added that tries to guide the board into the saw, but this turned out to be finicky. Suffice it to say that an air compressor and a handful of non-LEGO-approved components created a pretty convincing table saw.

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Building A Tiny Table Saw

May 22, 2025 by Zoe Skyforest 29 Comments

If you want a regular table saw, you’re probably best off just buying one—it’s hard to beat the economies of scale that benefit the major manufacturers. If you want a teeny one, though, you might like to build it yourself. [Maciej Nowak] has done just that.

The concept is simple enough; a small motor and a small blade make a small table saw. [Maciej] sourced a remarkably powerful 800-watt brushless motor for the build. From there, the project involved fabricating a suitable blade mount, belt drive, and frame for the tool. Some time was well-spent on the lathe producing the requisite components out of steel and aluminum, as well as a stout housing out of plywood. The motor was then fitted with a speed controller, with the slight inconvenience that it’s a hobby unit designed to run off DC batteries rather than a wall supply. Ultimately, though, this makes the saw nicely portable. All that was left to do was to fit the metal top plate, guides, and a suitably small 3″ saw blade to complete the build.

We’ve seen mini machine tools like these before, too. They can actually be pretty useful if you find yourself regularly working on tiny little projects. Video after the break.

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Tricked Out Miter Fence Has All The Features

February 22, 2025 by Dan Maloney 3 Comments

“World’s best” is a mighty ambitious claim, regardless of what you’ve built. But from the look of [Marius Hornberger]’s tricked-out miter fence, it seems like a pretty reasonable claim.

For those who have experienced the torture of using the standard miter fence that comes with machine tools like a table saw, band saw, or belt sander, any change is likely to make a big difference in accuracy. Miter fences are intended to position a workpiece at a precise angle relative to the plane of the cutting tool, with particular attention paid to the 90° and 45° settings, which are critical to creating square and true joints.

[Marius] started his build with a runner for the T-slot in his machine tools, slightly undersized for the width of the slot but with adjustment screws that expand plastic washers to take up the slack. An aluminum plate equipped with a 3D printed sector gear is attached to the runner, and a large knob with a small pinion mates to it. The knob has 120 precisely positioned slots in its underside, which thanks to a spring-loaded detent provide positive stops every 0.5°. A vernier scale also allows fine adjustment between positive stops, giving a final resolution of 0.1°.

Aside from the deliciously clicky goodness of the angle adjustment, [Marius] included a lot of thoughtful touches. We particularly like the cam-action lock for the angle setting, which prevents knocking your fine angle adjustment out of whack. We’re also intrigued by the slide lock, which firmly grips the T-slot and keeps the fence fixed in one place on the machine. As for the accuracy of the tool, guest meteorologist and machining stalwart [Stefan Gotteswinter] gave it a thumbs-up.

[Marius] is a veteran tool tweaker, and we’ve featured some of his projects before. We bet this fence will see some use on his much-modified drill press, and many of the parts for this build were made on his homemade CNC router.

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Man using a table saw with a VR headset on

Chop, Chop, Chop: Trying Out VR For Woodworking

February 15, 2025 by Heidi Ulrich 23 Comments

Virtual Reality in woodworking sounds like a recipe for disaster—or at least a few missing fingers. But [The Swedish Maker] decided to put this concept to the test, diving into a full woodworking project while wearing a Meta Quest 3. You can check out the full experiment here, but let’s break down the highs, lows, and slightly terrifying moments of this unconventional build.

The plan: complete a full furniture build while using the VR headset for everything—from sketching ideas to cutting plywood. The Meta Quest 3’s passthrough mode provided a semi-transparent AR view, allowing [The Swedish Maker] to see real-world tools while overlaying digital plans. Sounds futuristic, right? Well, the reality was more like a VR fever dream. Depth perception was off, measuring was a struggle, and working through a screen-delayed headset was nauseating at best. Yet, despite the warped visuals, the experiment uncovered some surprising advantages—like the ability to overlay PDFs in real-time without constantly running back to a computer.

So is VR useful to the future of woodworking? If you’re a woodworking novice, you might steer clear from VR and read up on the basics first. For the more seasoned: maybe, when headsets evolve beyond their current limitations. For now, it’s a hilarious, slightly terrifying experiment that might just inspire the next wave of augmented reality workshops. If you’re more into electronics, we did cover the possibilities with AR some time ago. We’re curious to know your thoughts on this development in the comments!

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Tech In Plain Sight: Table Saw Safety

December 17, 2024 by Al Williams 76 Comments

If you ask around a wood shop, most people will agree that the table saw is the most dangerous tool around. There’s ample evidence that this is true. In 2015, over 30,000 ER visits happened because of table saws. However, it isn’t clear how many of those are from blade contact and how many are from other problems like kickback.

We’ve seen a hand contact a blade in a high school shop class, and the results are not pretty. We’ve heard of some people getting off lucky with stitches, reconstructive surgery, and lifelong pain. They are the lucky ones. Many people lose fingers, hands, or have permanent disfiguration and loss of function. Surgeons say that the speed and vigor of the blade means that some of the tissue around the cut vanishes, making reconstruction very difficult.

Modern Tech

These days, there are systems that can help prevent or mitigate these kinds of accidents. The most common in the United States is the patented SawStop system, which is proprietary — that is, to get it, you have to buy a saw from SawStop.

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Homemade SawStop Attachment Is Just About As Sketchy As It Sounds

August 2, 2022 by Dan Maloney 56 Comments

TL;DR — when [Colin Furze] is your “safety inspector,” you really should be reconsidering your project goals.

Most of us have probably by now seen the SawStop brand of self-stopping table saw, which detects when something meatier than wood has the bad taste to touch the spinning blade, more or less instantly stopping it and preventing sudden traumatic amputations. It’s an outstanding idea, and we’d love to see the technology built into all table saws. But alas, SawStop saws are priced out of reach for many woodworkers, which left [Ruth Amos] to roll her own DIY version of the system.

It should be stated right off the bat that none of what [Ruth] does here is a good idea, and that everything shown is really just a proof of concept. The basis for her build was a somewhat flimsy-looking contractor-style saw, to which [Ruth] attached an Arduino set up to detect when something conductive touches the blade. She shares no particulars on the sensing method, but our guess is capacitive coupling. She then sets about experimenting with a series of above-table gizmos to arrest the blade, with limited success, plus all the attachments would make the saw essentially useless. But working above the table does make sense in the prototyping phase, and allowed her to figure out what wouldn’t work.

In the end, it was an electromagnetic clutch from an electric lawnmower that seemed to do the trick, albeit at the expense of heavy mods to the saw and a considerable increase in the system’s angular momentum. Nonetheless, the blade stops pretty close to instantly in the old hot dog test. It doesn’t drop the blade below the table, of course, and the hot dog is a little worse for the wear, but it’s still pretty impressive.

We’ve discussed SawStop’s technology before and why it isn’t perhaps as widely available as it should be, if you’re curious.

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Brick And Motor Table Saw Delivers Paper Cuts On Demand

March 23, 2022 by Ryan Flowers 11 Comments

Twenty Two Motors. Fifty gears. Eighty Two Hundred RPM. Hundreds of individual pieces, and one sheet of glossy paper cut into a disk. This isn’t a nightmare driven Rube Goldberg machine. Instead, it’s a Lego monstrosity created by [GazR] of [GazR’s Extreme Brick Machines!], and all of these parts are flying in formation for one Lego slicing purpose. In the video below the break, you can see what very well may be the worlds most powerful Lego and Paper table saw.

Starting out with a build that had a mere fourteen motors in a platform that looked quite a lot more like a table saw, [GazR] learned that having only fourteen motors turning a Lego based blade was not a good combination. In the next iteration, the same number of motors were used, but the gearing was increased to bring RPM up, and a Lego toy saw blade took care of cutting duties.

Seeing that higher speeds with thinner blades was a winning trend, [GazR] stepped it up to the aforementioned 8200 RPM twenty-two motored paper whirling Lego Death Machine. Yes, [GazR] cut Lego, carrots, carpet, and paper- all with circular sheet of paper.

Do Lego mechanisms turn your gears? You might enjoy this Legopunk Orrery from the Hackaday archives, too. Thanks to [Keith] for the great tip. Be sure to submit your own tips via the Hackaday Tips Line, or the #Submit-A-Tip channel in the Hackaday Discord server.

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