Extend-A-Saw
Case Study · Construction Equipment · Mechanical Engineering
The brief
We were approached by an inventor who wanted to turn his portable table saw into a full-sized version for remote on-the-job construction. Contractors love the portability of a jobsite saw, but ripping wide sheet goods on a small table is awkward and unsafe — the choice had always been portability or capacity, never both.
What we did
We did just that. The Extend-A-Saw converts a portable table saw into a full-sized cutting system anywhere a contractor can carry one. Key engineering decisions:
- Universal fit — the design adapts to a large variety of table saws rather than locking the owner into one brand.
- Expansive wing design — durable folding extension wings make cutting narrow or wide material equally routine.
- Extruded aluminum construction — a deliberate material choice: stiff and flat enough to keep the extended table true, light enough to stay genuinely portable, and tough enough for truck-bed life.
The result
A durable workhorse of a portable table that gives a jobsite saw the working surface of a cabinet saw — the kind of tool that finds its way into every contractor's truck. The project ran from concept through CAD, prototyping, and design for manufacturing.
