How I re-engineered my Table Saw Dust Collection from Scratch using 3D Printing
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- เผยแพร่เมื่อ 23 มี.ค. 2024
- My table saw (Holzmann TS 250) is great overall, but its lack of proper dust collection has been annoying ever since I got it. In this video I'm showing you how I fixed it by building an entirely new dust collection system for both inside the saw and on top, using mostly 3D printed parts and lots of prototyping.
📐 3D files for Dust Box inside the Saw: philvandelay.etsy.com/listing...
📐 3D files for the Dust Hood: philvandelay.etsy.com/de-en/l...
🔧 LINK LIST for tools I use in my videos: hero.page/philvandelay/my-fav...
👕 SHIRTS / Merch Store: phil-vandelay.creator-spring....
🙏🏻 Patreon: / philvandelay
📷 Instagram: / phil_vandelay
Here's some videos that inspired my Dust Hood Design:
• DIY Dust Hood and inte...
• How to Make a Table Sa... - วิทยาศาสตร์และเทคโนโลยี
![[TH] 2024 PMSL SEA W2D3 | Summer | ไม่อยากเหนื่อยวันเสาร์ ก็ต้องจัดเต็ม](http://i.ytimg.com/vi/CbsHmoJXjvE/mqdefault.jpg)
“I’m gonna do the most woodworking thing possible and talk about dust collection” 😂 this is such an accurate statement
Let’s not overlook the similarly over-discussed topic of table saw sleds…
that and sanding.
This is the most elaborate exercise in solving the tricky problem of dust collection (capture >95% fines) of the central machine in any woodshop. I struggled with the same problem in trying to fix the poorly designed (afterthought as you mention) dust shroud in my Grizzly cabinet saw. The best I could do was get about 80% of the fines and keep the tabletop dust to 50% before the fix. You should win an award for The 'BESPOKE DUST COLLECTION SYSTEM" of the YEAR
2:00 😂😂😂 compositing this photo was a good use of your time, it gave me a huge laugh
Yes, wanted to mention it, too.
Table saws are really the 'final boss' of dust collection. Even after all the innovation and work of solving the bottom, you still have to solve the top. You really did an amazing job here
Hallo Phil, Du hast genau die Probleme dieser Säge aufgezeigt und gelöst. Wir betreiben die Säge in unserer Seniorenholzhobbywerkstatt seit drei Jahren und auch schon einiges daran verbessert. Als erstes den Maschinenschalter nach vorne und auch eine Bürste in die Schlitze der Kurbel bzw. dem Festklemmer der Winkeleinstellung. Das größte Problem aber hast Du jetzt mit dem Kasten und der Veränderung gelöst. Es gab zwar bei anderen TH-cam-Aktivisten Lösungsansätze, aber das was Du da erstellt hast ist großartig. Mir ist jetzt erst Klar geworden, wo das eigentliche Problem liegt. Gerne würden wir unser Holzmann Kreissäge so auch umrüsten.
I am envious of this setup and will need to try printing some of these bits! For what its worth, heres something i discovered when trying to do dust collection on a buffer - the fast spinning blade essentially creates its own eddy which prevents dust collection. The only solution is to allow more airflow - i suspect that your shroud on the bottom is actually too narrow . Screens or bristles can be a lot more effective at closing in areas because they allow airflow IN but prevent chips from escaping. In my case a large box was more effective at fine dust collection than afitting shroud. Something to consider of you ever find yourself wanting to get additional capture. But what you've made is phenomenal!
I agree with this analysis, but this applies primarily to the large particles where you need more airflow to redirect particles with more momentum. For the fines, this was adequate.
i've been wanting to print something like this for my table saw for so long. its so nice to see that i wasnt the only one having the dust spit issues with a table saw. love the build and the the issues/solutions shown. will def help me when i finally have time to make these prints.
Put bristles at the end of the shroud.
I thought about that but unless the bristles are signficantly longer than your workpiece thickness you'd still end up with a gap at the end while also losing suction
@@PhilVandelay Would those 70mm bristle CNC vacuum strips work for you?
Possibly, it's just that I've never seen anyone use this approach for a table saw and I figured there's probably a reason. Might be worth a try, but for now I don't want to spend any more time on this
@@PhilVandelayI was gonna suggest something similar, but not bristles: just add a short 3d printed (straight) piece to the front edge of the cover which is essentially extending the curved part, but can pivot. Once the piece of wood passes underneath, it drops to the table saw surface and essentially provides a ramp into the curved hood for the stuff that get's thrown out under the cover from the blade at the end. Watching the clips, the escaping particles are only a problem once the saw blade is starting to cut the back edge of the piece of wood, and by then this "ramp" would have dropped and likely catch a large portion of those.
How about sealing the bottom with another sheet of polycarbonate and using the saw to cut its own slot? That might seal it even better
Of all the videos I've seen on the subject, your solution is by far the most effective. I say this because I myself spent a lot of time thinking about the problem without ever finding a real solution. Well done 👍
Incredible Analysis, Design and Execution
One improvement I'd love to try on your set-up is a flappy bit or brush that sits between the curved front and the blade like a scoop. Visible at around 20:28
Making it a zero clearance style scoop means that the shroud won't have a big gap underneath it as it's lifted by the work material, so you'd also collect most of the chips not just fines.
Amazing build! I'm definitely stealing this concept for my mitre saw aka the dust cannon.
Beautiful and inspiring work! Great job.
Very nice work! Well done! I will definitely have to watch this video again, probably a few times.
At this point, two areas for possible further improvement jumped out at me: a few other commenters have suggested adding some kind of bristles at the front of the blade guard/dust hood; and a few have also mentioned the importance of adequate air flow.
Really liked the way you broke the problem down - some pieces are stationary, while others move with the blade. Most folks would have missed that.
Great work! I found myself constantly nodding in agreement to what you're concluding based on my own experiences and tests.
That's an enormous improvement, impressive stuff! Like you indirectly said in the video, there's a point of diminishing returns in terms of effort, time, money and resources put into a project. Specifically for the zero clearance inserts, that's literally the perfect solution in terms of "keep it simple stupid".
There's always going to be people in the comments who never built anything in their life complaining lol
Yeah I think especially with the dust hood on top you could keep experimenting with different designs endlessly, as I hinted at in the beginning the whole dust collection thing is a neverending rabbit hole
Chapeau. Very clever engineering and great solution to the issue. I just got the TS250 and am drowning in dust as well. I'd appreciate if you could share your design files for the dustbox. Thanks a ton.
Incredible, I really liked the way you designed and customized it.
Very cool. Love you use and explanation of the design process throughout.
I love your work Phil, nicely done.
Amazing work!! If & when I get a workshop I’ll buy the same model saw just because of this excellent design for dust.
Really nice design.
Excellent design and execution sir!
Beautifully designed solutions, nice work!
I was hooked from the intro on! Smart and witty! I smiled the whole way through
This was great mate, that was good problem solving and I loved the self aware commentary on what garage shops are all about 😁
Looks quite effective and a happy relief for you. As you were talking us through it I was thinking that it is necessary to keep enough inlet open area to keep maximum velocity to entrain the particles with the air flow. I chuckled once when I joined a company and one of my challenges was to solve a problem with a machine that had 250 cfm flow through a ... closed box! Not too challenging for me to solve. Same principle here.
Very nice job and well presented! I love it and inspired to do similar with my shopsmith!
I admire your use of magnets and your fearless pursuit of these innovations! Great job!
awesome results, great design!
Amazing work, well done!
I'm so proud of you. Great job. I wish I had a 3D printer all the time for so many random ideas like this.
What timing! I bought my first saw table today, and yeah this is necessary.
Excellent design and explanation!
Amazing work dude.Awsome.
Quite spectacular, thank you so much for sharing your great project 🤩🤩
Excellent video in all aspects! Simply superb! Thank you!
Hi Phil - great video 😊 - I have the same table saw (Holzmann TS250) - and I also tried to figure out the dust collection problem some time ago, but kind of postponed it until I got "the good idea". Thank you for sharing - now I think I will redesign my table saw inspired by you ...well done.
Nice work Phil, good engineering and an excellent illustration of problem solving. Shame there wasn't some welding this time, you do that well and it's fun to watch. Thanks for the explanation, really clear and concise.
Attention to detail ... Nice clear concise and on point Execution
Nicely done. I bought the file yesterday but I need to do some change to attached to the 2.5" dust collection hose.
I have this exact saw and would be very happy to get the dust box files from you 😊
Brilliant work
Very nice dude! I'm going to try and build this as well!! Thanks for the idea, because that fine dust is driving me crazy!!
Phil-awesome as always. Been watching for a while and your channel is amazing.
Clever use of the slot and washer to sustain planar alignment!
Impressive results!
Awesome work man and time to figure out all the other crappy table saw dust collection!
A flexible brush at the dusthood end might be able to deaccelerate the bigger particles to increase the chance of them being sucked in eventually.
Great video, subscribed! This is the reason why 3D printing is such a revolution for people like us. It allows us to design, prototype and print things that most manufacturers cut to save on product cost. I find that 99% of tools I purchase can be improved in some way, so I love this video.
Absolutely, making this from sheet metal would have been a nightmare, especially if you want to do rapid prototyping. I probably wouldn't have touched this problem were it not for the option of having my printer do the grunt work
Hi Phil, GREAT JOB👍 I use the same saw (Holzmann TS 250) and this is exactly what I've always been looking for. I don't use a 3D printer, is it possible to order a complete set which were shown here in the video? Cheers!!
Absolutely brilliant work!!! 👏 👏👍👍
Man, this is a great video :D i have the same tablesaw, and wondered why i had a huge amount of sawdust under it..
I will try and recreate something like this. Lovely to know the sides are removable
The simplest and most effective dust collection I've seen is just removing the box and sealing off the bottom and putting the suction hose at the bottom. Then get some magnetic sheets and put them across the gap at the front so the blade can still tilt.
Like an actual cabinet saw.
That is how most of the higher end saws I have seen work
Very nicely done!!
I don't have the same saw, but there are some great ideas here for the old Craftsman I do have. Thanks!
Well done! Nice Video.
For the hood, you could attach a small flap at and angle with a spring so when you push the material it rides on top of it and once you reach the end of the cut it can drop down and hopefully reduce that burst of particles.
Nicely done
Fantastic job. Wish I could do that to my saw.
Holes to the right of the blade in the zero clearance insert will allow more airflow, possible improving dust collection above and around the blade
Do you mean to the left of the blade? The right side of the insert would be covered by the wood. See "Hooked on Wood" to see how Dennis engineered the HOW Zero Clearance insert. He's a lot like Phil here--a born engineer.
Very good results.
It's a good upgrade, I made it in my way on mine machine's, it's not easy but it's possible, thank you.
That's a solid result. I wonder whether a wide-mouth intake fit level along the outfeed side of the table would catch those few remaining large chips. The cut wood would pass over it so it might remove chips stuck to the newly cut surfaces, too.
great work here! thanx for sharing...
I actually love those videos where wood workers make an over the top and/or robust dust collectors. My favorite is the one that Marius Hornberger made.
Marius is definitely on another level in this game!
Nice Work!
As a machinist and fellow metalworker, you give me faith to venture into the deep, dark, gross, disgusting, and foul depths known as woodworking
What an awesome job.
You can try to use a flexible (TPU?) lip on the front of the top cover, then it might be able to close the gap while the board moves.
tae a look at the sawstop guard, its similar but has a channel to the front to concentrate the suction, plus additional dropdown shields on the side.
Very well done.
im thinking of adding some brush bristles around the dust hood that's over the blade, like the brush around a CNC router. and also some upside down bristles in front of the saw fence rail.
Your commentary is hilarious. Great job.
Great mods, Super graphics 👍. And guys always wear a good dust mask, especially if it’s not sold wood. The glues are bad stuff.
In making things remember eye, ear, lung, and skin protection. Yes skin, even if it doesn’t harm the skin, it can be absorbed.
Well done
You may want to try a small brush strip at the leading edge of the dust hood over the blade. It might slow the larger particles down long enough to be caught up in the suction.
excellent beautiful work
A+ really well done.
I did something similar but added another sliding box outside the main box to be able to have maximum coverage at all angles. I never made it self adjusting so you had to change it everytime. Was fun. Unfortunately the effort wasn't worth the saw I put it on and I have now a better saw.
Love your video. You also have awesome skills. ❤
Very nice design, Phil. I like the magnets most. Makes everthing nicely maintainable. Something I would have done differently would be to think of flexible parts or even textile parts so that the dust box can move freely while everthing stays enclosed in any position. Maybe some kind of broom or vacuum cleaner hairs which close the gap when the saw is upright and bend against the dust box when the saw is tilted - or a leather or linen enclosure...
Anyway, well done.
Nicely done! The only thing you really need at this point is more CFM! A shop vac is only going to provide around 80-110 CFM. Most Table saws are going to require around 550 CFM.
Great job, Thanks.
This was a great example of analysis followed by iterative design refinement, thanks very much for sharing. I only wish you were a sliding miters user. Dust collection on those needs your kind of analysis and design!
This is what I’m talking about. Dust collection needs to be more customizable like this
Well done! One thing that might improve the dust collection of the heavier chips would be to attach a drop-down guard at the bottom of the rounded front in the shape of a hollow wedge, so that the sides is covered while the blades throw line is covered. Not sure If I make any sense, but just make a hinge on the bottom of the part you glued in that drops down the wedge as the wood passes by.
Yeah I've actually seen hoods like that but the main problem seems to be that it wants to shoot out straight to the front as you exit the cut, not so much the sides. I also thought about having something drop down in front to close that gap but couldn't really think of a good solution that works with varying blade settings. I think you could keep working on this endlessly and probably improve it a lot more but I wanted to be done with it 😅
@@PhilVandelay would brushes around the hood help?
Money aside air volume per minute is the no 1 functionality breaker as dust collectors concern!
Kind regards/A
Add a small rubber/silicone flap to the front of the top intake so when the working piece is past the front of the top intake the flap extends down and directs the chunks up into the intake.
Excellent work and a good idea. I have the same saw myself and know a few people who have the same problem with the saw's miserable dust extraction.
I have already modified the dust extraction system. But your dust extractor is just great. Question: Can you provide the stl files for the saw blade extraction in any way?
In any case, thank you very much. 👋👋👍👍👍👍👍
Well.... I solved this problem by getting the biggest skyscraper dust collection system i could find which fits in my garage. But well done mate. You are officially crazy 😂
Excellent work! One suggestion: A front pivot or double pivot top shroud would be even more effective, as it would close the side gaps between the hood and wood
Since you have already gone way overkill, which I love, could you also add a spring-loaded shield that falls onto the table top after the end of the material passes beyond the upper collector? Similar to a circular saw.
I don't have the saw but man, that's an ingenious solution!
What an awesome piece of work, congratulations. I'm sure I have the same saw, with the same problems but mine is badged and painted differntly. Either that, or it's incredibly similar. After hours spent with the side panels off trying to clear sawdust out of the way your video was like looking inside my own. Even with a big, 100mm dust extractor on a 2m hose it's rubbish.
Is there any way you could post the CAD and other info for the dust cage and zero clearance throat somewhere like Github or similar? If the dimensions are anything like similar to mine I'll go out and buy a 3D printer just to fix it!
Hello Phil
Thank you for this excellent documentation, better tutorial. Just repeating the positve remarks below: excellent analysis. design and craftmansship!
Do you think a kind of brush would help to capture the "final" dust particles?
Some CNC maschines for wood using sometimes brushes to reduce the "flying dust particles".
I wish you a happy easter
Kind Regards - Andreas
That opening statement... 😂 👌
You could improve the dust hood on top by making the curved part a little lower, as dust seems to now shoot under it. If you make this end up at the height where a standard board (the normal size you'd use this with) would have the hood rest on the table itself once it slips past it'll close that gap, where it now instead leaves a gap as the board pulls up the hood.
You could even make this a little flexible extension for the dust hood, or attach a brush to it, as all it needs to do is stop the dust shooting out so that it can be sucked up.
Nice design work. Very well done. Really good video too. I wonder how much the zero clearance insert would improve the standard dust collection. lots of great ideas.
Yeah I thought about that too, maybe it could have worked with the old box. Then again I'm not sure it would have worked out clearance wise
Geile Lösung und das Video ist auch echt gut gemacht
This is such a good video. Many have struggled with ideas but you did great at implementing what you did. I never thought of 3d printed insert. I have a saw like yours with that annoying top rod that wants to be close to the table surface. That is the cheap design compared to Unisaw and top models. Anyway, model it once, which is tricky as other odd forms are involved with holding that pivot rod and so on. Then reprint as needed for straight cut and angled. My overall thought is dust below the table is best captured by a sealed bottom platform box. You need cooling air for motor so a few vent holes but then not fancy shrowd needed right? Still need top thingy as tons of dust comes from the top.
A Dewalt Jobsite saw already has a better dust shroud, with the blade and motor moving and a fabric portion. The problem is the blade shooting dust at the cutting point straight back at you. That's the hard nearly impossible to catch dust that flies at speeds that would require 1000 CFM at 100 m/s
brilliant!