How I re-engineered my Table Saw Dust Collection from Scratch using 3D Printing

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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...

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23 мар 2024

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Комментарии : 272

@TobaccoTooling Месяц назад

“I’m gonna do the most woodworking thing possible and talk about dust collection” 😂 this is such an accurate statement

@WJR1965 Месяц назад

Let’s not overlook the similarly over-discussed topic of table saw sleds…

@01sigh Месяц назад

that and sanding.

@rsc4peace971 Месяц назад

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

@rootvalue Месяц назад

2:00 😂😂😂 compositing this photo was a good use of your time, it gave me a huge laugh

@dieterjosef Месяц назад

Yes, wanted to mention it, too.

@acanadianwoodworker 23 дня назад

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

@rudolfpeters367 Месяц назад

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 RU-vid-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.

@guitarchitectural Месяц назад

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!

@steveh8724 Месяц назад

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.

@stephmo371 Месяц назад

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.

@trobinou47 Месяц назад

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 👍

@Oysteims Месяц назад

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

@PhilVandelay Месяц назад

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

@Nachdenksport Месяц назад

Great work! I found myself constantly nodding in agreement to what you're concluding based on my own experiences and tests.

@joedance14 Месяц назад

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.

@bkdiyprojects6641 Месяц назад

Incredible Analysis, Design and Execution

@Drokkstar_ Месяц назад

Beautiful and inspiring work! Great job.

@benbrubaker7896 11 дней назад

Very cool. Love you use and explanation of the design process throughout.

@toddharshbarger8616 Месяц назад

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!

@AriasThirdOfHisName Месяц назад

This was great mate, that was good problem solving and I loved the self aware commentary on what garage shops are all about 😁

@raulc398 Месяц назад

Put bristles at the end of the shroud.

@PhilVandelay Месяц назад

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

@schulzcbs Месяц назад

@@PhilVandelay Would those 70mm bristle CNC vacuum strips work for you?

@PhilVandelay Месяц назад

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

@TheCreat Месяц назад

@@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.

@tanyeewei Месяц назад

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

@virtualburton Месяц назад

I love your work Phil, nicely done.

@abbumahdi Месяц назад

Incredible, I really liked the way you designed and customized it.

@thomasbroker69 Месяц назад

Amazing work!! If & when I get a workshop I’ll buy the same model saw just because of this excellent design for dust.

@rudispruell883 Месяц назад

I was hooked from the intro on! Smart and witty! I smiled the whole way through

@chrisomahony7166 Месяц назад

Beautifully designed solutions, nice work!

@beaker2000 Месяц назад

Really nice design.

@thimtools7538 Месяц назад

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.

@akinadom Месяц назад

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.

@akquicksilver Месяц назад

Excellent design and execution sir!

@temyraverdana6421 Месяц назад

Amazing work, well done!

@lewchishelltaya5745 Месяц назад

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.

@RCake Месяц назад

Quite spectacular, thank you so much for sharing your great project 🤩🤩

@polidactDIY Месяц назад

awesome results, great design!

@Tsitris46 Месяц назад

Phil-awesome as always. Been watching for a while and your channel is amazing.

@danilogujtman6140 Месяц назад

Amazing work dude.Awsome.

@user-wh7cl7vc4i 12 дней назад

Excellent design and explanation!

@SomewhatAbnormal Месяц назад

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.

@PhilVandelay Месяц назад

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

@RickRolling-tc7vb Месяц назад

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.

@dittilio 29 дней назад

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.

@heinrichhemker8123 Месяц назад

Excellent video in all aspects! Simply superb! Thank you!

@sam-bn5hl Месяц назад

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!!

@jamieclarke321 Месяц назад

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

@eoresco1 Месяц назад

Brilliant work

@drpipe Месяц назад

Attention to detail ... Nice clear concise and on point Execution

@lint2023 Месяц назад

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.

@davids8493 Месяц назад

Absolutely brilliant work!!! 👏 👏👍👍

@thorshuatus Месяц назад

Awesome work man and time to figure out all the other crappy table saw dust collection!

@marci0309 Месяц назад

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

@SimonsWerkstatt Месяц назад

I have this exact saw and would be very happy to get the dust box files from you 😊

@LewHarriman Месяц назад

Impressive results!

@criggie Месяц назад

What timing! I bought my first saw table today, and yeah this is necessary.

@unogazzy84 Месяц назад

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.

@PhilVandelay Месяц назад

Marius is definitely on another level in this game!

@LT-gj3rm Месяц назад

Nicely done. I bought the file yesterday but I need to do some change to attached to the 2.5" dust collection hose.

@LeoWal01 11 дней назад

Very nicely done!!

@edwardchester1 Месяц назад

That opening statement... 😂 👌

@juliankoenig Месяц назад

Well done! Nice Video.

@ralfklosener6981 Месяц назад

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!!

@saschma3543 Месяц назад

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 😂

@JohnChuprun 24 дня назад

Nicely done

@michaelrobinson9643 Месяц назад

Clever use of the slot and washer to sustain planar alignment!

@iteerrex8166 Месяц назад

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.

@shakdidagalimal Месяц назад

A+ really well done.

@chrismayer8990 Месяц назад

Nice Work!

@MiloslavPetrtyl Месяц назад

great work here! thanx for sharing...

@iDoPew Месяц назад

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.

@TouchofDepth Месяц назад

excellent beautiful work

@jimsvideos7201 Месяц назад

Very well done.

@gragaloth6237 Месяц назад

As a machinist and fellow metalworker, you give me faith to venture into the deep, dark, gross, disgusting, and foul depths known as woodworking

@VAXHeadroom Месяц назад

I don't have the same saw, but there are some great ideas here for the old Craftsman I do have. Thanks!

@regibson23 Месяц назад

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.

@cmmartti Месяц назад

Like an actual cabinet saw.

@Mike_Rogge 9 дней назад

That is how most of the higher end saws I have seen work

@kenzeiszler8213 Месяц назад

Fantastic job. Wish I could do that to my saw.

@Fusion_Woodworking Месяц назад

Very good results.

@shanespence7461 Месяц назад

Love your video. You also have awesome skills. ❤

@bradleytuckwell4881 Месяц назад

Well done

@fritziii2137 Месяц назад

Your commentary is hilarious. Great job.

@GT40Nut 13 дней назад

Great job, Thanks.

@Moinois Месяц назад

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.

@PhilVandelay Месяц назад

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 😅

@ApolloWoodwork Месяц назад

@@PhilVandelay would brushes around the hood help?

@kotqrka Месяц назад

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.

@jamescollier2049 Месяц назад

This is what I’m talking about. Dust collection needs to be more customizable like this

@funfreq9282 Месяц назад

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.

@dleivam Месяц назад

brilliant!

@kekunfica Месяц назад

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.

@robertsternlieb5532 Месяц назад

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.

@PhilVandelay Месяц назад

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

@sunc93 Месяц назад

Geile Lösung und das Video ist auch echt gut gemacht

@OhHeyTrevorFlowers Месяц назад

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.

@djvitornunes 15 дней назад

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.

@mattsalive7614 Месяц назад

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

@steveh8724 Месяц назад

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!

@kleckerklotz9620 Месяц назад

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.

@wafflebeaver Месяц назад

This is some unreal engineering. Corporations fail at engineering dust collection like this but a guy in a small shop can figure this out. What a world we live in…

@jaguar36 Месяц назад

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.

@tomfull6637 Месяц назад

Money aside air volume per minute is the no 1 functionality breaker as dust collectors concern! Kind regards/A

@technix01 Месяц назад

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. 👋👋👍👍👍👍👍

@aaronalquiza9680 Месяц назад

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.

@williamwampler7742 25 дней назад

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.

@undaware Месяц назад

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.

@manvenderrawat2869 Месяц назад

Excellent

@MrAndrew990 Месяц назад

love the woodworking slander

@lightspeed1755 Месяц назад

You might consider designing the stiffening ribs for that dust box cover on the outside, so they don't catch fine particles and [further] turbulate airflow inside

@PhilVandelay Месяц назад

That's actually a very good suggestion. Seems obvious in retrospect but never even crossed my mind

@jamesont6472 Месяц назад

I appreciate the introduction, at least for me the entire point of dust collection is the tiny particles as I'm not able to inhale mulch. Well, have fun in the shop I reckon! Pro tip: don't put your fingie where you wouldn't put your dingy.

@IanThompson-ln3bo Месяц назад

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!

@dickverboom4379 Месяц назад

There is a channel Hooked on Wood were you can find his experiment with an insert that has air slots to improve the airflow into the suction hose. His logic is that airflow out has to have a way of air getting in otherwise you just get a kind of vacuum. Airflow is what moves your dust.

@PhilVandelay Месяц назад

Interesting, I'll have a look at that