Mini 3in Brushless Chop Saw

3D Printed Mini Chop Saw – V1 (3 Inch Cut-Off Discs)

It in action and a little 360 action:
https://www.youtube.com/shorts/uJnDjB239q0

This is my first version of a fully custom 3D printed mini chop saw designed to use 3-inch cut-off discs. I wanted a mini chop saw for small wires and rods to precise lengths. The commercial ones are really low torque and have a cable. I wanted mine to be battery operated and also to use a brushless motor. It uses Makita batteries but other version for all kinds of batteries can easily be made.

For the motor and controller, I used a cheap Hilda 3-inch cut-off tool and relocated the switch to the handle for easier operation.

Features
Compatible with 3-inch (76 mm) cut-off discs
3D printed vise and adjustable stop block
Built-in drawer for storing spare cutting discs
Hex key storage slot inside the handle
ABS printed springs
Custom 3D printed thrust bearings using steel balls recovered from three old 6001 bearings
Four 608 bearings and an 8 mm shaft
Various M8 bolts, nuts, and washers

Things to Improve

This is only V1, and I've already found plenty of things I'd like to change.

Wire management definitely needs improvement, and I'm considering moving the vise to the opposite side and redesigning it to make it stronger.

Another major concern is sparks and dust. Since the machine is mostly plastic, hot sparks could damage or melt some of the printed parts. I'll probably need to add some sheet metal shielding and work on better dust collection.

I'll be making a full assembly video in the next day or two, showing how everything goes together and will link it here. There are some things I'm kinda proud of and lot of things I would and will change.

Overall, this was a fun little engineering and 3D printing exercise. It's far from perfect, but that's the point of V1! I already have plenty of ideas for the next version.