Toy Hand Saw

Just a simple toy hand saw. 

Needs some adjustment on the handle part to get a good fit- but this depends on your slicing settings. 

Start with the blade; position it flat on the build plate, slice it with your desired settings, and measure the actual thickness (count the layers in your slicer).

Now the handle; position it flat, and adjust the Z axis scaling on the handle to provide enough space for the blade to be pressed or glued in place in the pocket. 

Example

I always use a 0.2mm first layer height, and printed both parts in 0.3mm layers. My blade ended up being 14 layers or 4.1mm thick. 

The pocket in the handle is (once sliced using the above settings) 13 layers thick (all of these layers are 0.3mm) so 3.9mm in total and not wide enough for the blade. 

Solution: change the Z scaling (only) to 4.1 / 3.9 = 105%. Now re-slice the handle and the pocket is now 14 layers 4.2mm thick. All is well in the world. 

Print both items flat. No supports required on the blade. Supports are required on the handle. 

I have printed this successfully but didn't photograph before handing it over to the apprentice. I'll update with some photos when I get a chance.