saw handle
prototyping process
The handle project had a goal to show the prototyping process from start to finish. Starting at foam model development, to hard models, to resin casted prototypes. This project lasted one and a half semesters, during my final year at Dawson College Industrial Design. I was assigned to redesign an all purpose push-pull saw handle.
phase one: foam model concept development
phase two: basswood hard modelÂ
phase three: making the final prototype
the process starts by making a renshape master model. Then, a two-part mold is cast out of silicone around the master. This mold can then be used to cast urethane handles repeatedly.
two blocks of renshape
styrene template
rough trimming
milling to thickness
router profile with template
milling step down
glueing halves together
rounding edges
verified with profile templates
body filler for inside fillet
finishing body filler
casting box
measuring silicone
silicone casting
demolding renshape
preparing for urethane casting
part A and B of resin
mixing in the dye
injecting resin
demolding casted handle
drilling fastener holes
counter-boring fastener holes
creating blade slot
final three handles
