12 weeks · product design · summer 2024

Meet the FESTOOL DEXTRO.

A versatile, sub-compact circular saw for the toughest demands.

QUICK INSIGHTS

Overview and Goals

Created in a 12 week studio project to design a handheld powertool.

The final product should be market relevant, versatile, and a simple to use.

Personal goals for the project were to elevate research and brand alignment skills.

immersive user research - independent

Local Contractor Shadowing

Mac is a Cincinnati contractor who works on a variety of team projects using handheld power tools. Shadowing and interviewing him revealed his preferred tools and brands, current projects, and an in-depth overview of the RIDGID SubCompact Cordless Saw.

“It’s a real handy little saw. You don’t have to carry those big saws around like the one I showed you, you can do almost just as much with this as you can with any of those other saws.”

- Mac R. III, Contractor

User experience mapping

Mini Circular Saw In-Depth

User experience mapping revealed that choosing to use a mini/subcompact circular saw presents several cognitive and physical challenges, leading to user pain points:

brand alignment

Why FESTOOL?

FESTOOL has an existing selection of popular specialty tools (shown: DOMINO biscuit joiner), supporting the addition of a cutting edge, unique tool like the subcompact saw.

Users trust FESTOOL for its durability, brand responsibility, and overall well designed products. It has a global, active community of enthusiasts.

FESTOOL is known for its modular and feature-rich designs, supporting the creation of accessories such as swappable blades or left-handed versions.

user and brand research

FESTOOL Brand Perception Survey

According to a survey sent to the FESTOOL forums, 71% of enthusiasts asserted that smoothness of form is the most important feature of the FESTOOL aesthetic.

Observational form studies analyzed the key aesthetic features of FESTOOL products, and an official branding guide was consulted for CMF and FESTOOL logo usage.

“Magnificent gear. I know they can do anything I am skilled enough to ask of them. The weak element in my woodshop is me.”

- "Fusepark," FESTOOL user quote

immersive user research - COLLABORATIVE

Shadowing a Loyal FESTOOL User

Ryan is a Cincinnati craftsman and self-described FESTOOL enthusiast and considers FESTOOL "the Cadillac of woodworking." He values for their brand reputation, superior dust collection, and organizational systems.

Visiting Ryan's woodshop allowed for hands-on time with over 25 FESTOOL products and for us to observe their use by an expert.

This research was done collaboratively with Zoe Hong, Gabriella Gibson, and Duy Nguyen. Photos by Duy Nguyen.

MARKET RESEARCH

Opportunity Insights

The subcompact handheld circular saw (SHCS) is available from both notable (Makita, DEWALT, Milwaukee, RIDGID) and generic brands. Market research revealed the lack of a professional grade, sleek version of this device, presenting an opportunity for brands such as FESTOOL.

Research on the FESTOOL product catalog shows the lack of a versatile, compact handheld cutting implement, which would be solved with the inclusion of a subcompact circular saw.

product research

Angle Grinder Teardown

A handheld circular saw was disassembled to better understand what components are found in a handheld cutting device. Unlike an angle grinder, the subcompact saw oscillates perpendicular to the surface.

The teardown informed the decision to use a brushless motor for its minimal weight and volume.

early ideation

Sketching and Early Models

Early sketches explored how to apply FESTOOL form language to the handle and head assembly. Concepts are designed around the FESTOOL 4.0 AH battery.

Sketches and foam models were created cocurrently to explore the same ideas in both 2D and 3D space.

concept development

CAD Development

DEXTRO was modeled in Fusion360 over 60 iterations. The design uses a FESTOOL 4.0 AH battery which was modeled from scratch based on reference photos.

Early models were rough blockouts with focus on silhouette and internal and external component position.
Intermediate models experimented with curvature and began replace blockout components
Later models focused on surface transitions, user touchpoints, and other fine details. Ribbing was added.

Final concept

Detail View

DEXTRO is features the FESTOOL EC TEC Brushless Motor and HighPower 18V 4.0 AH battery pack.

RenderS done in Blender.

Final concept

Product Features

Renders done in Blender, featuring a MetaHuman from Unreal Engine.

Final concept

Other Visualizations

DEXTRO was a great opportunity to learn about rendering CGI humans. Blender, Unreal Engine, and MetaHuman Creator were used to render DEXTRO in a completely digital environment.

Final concept

Surface Study Model and User Validation

A physical model was made of DEXTRO using CAM such as CNC milling and 3D printing. The model was used:

as a role-play prototype in ergonomics validation.
to analyze how light interacts with the surfacing in real life.
as a visual aid when presenting the product to final critique

Final concept

Final Presentation and Project Learnings

DEXTRO was presented at final critique to peers and industry professionals.

Key takeaways from this project:.

Qualitative research methodologies, and how to analyze and display findings
Construction and organizational techniques for complex, multi-part assemblies
How to prioritize/deprioritize tasks/features in order to meet a deadline/deliverable