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email: info@bigbluesaw.com

Customer Projects

Pemdas's Custom Keyboard with Waterjet Cut Plate

Our customer pemdas wrote to send us a photo of the keyboard he created with some help from Big Blue Saw.

The top plate was waterjet cut by Big Blue Saw from 0.063" thick aluminum 6061.

Here's what he had to say about our work:

Everything was perfect. Will definitely be using your services again for my future projects!


You guys made this so much easier than I thought it was going to be when I first started planning this project.


I keep thinking I should've ordered more than one just for the savings.

Pemdas also gave some details on the build:

I used vintage cherry blacks for the switches because I had a bunch of them laying around. They are linear switches and very smooth.



The outline was the easiest part! I used a tool made by a forum member named swill. I believe you guys worked with him as well for the water jet services.



My controller was the standard teensy 2.0 using the tmk firmware made by the another user named Hasu. That base plus a guide made by user matt3o made making the firmware super easy! No pcb meant handwiring which wasn't as bad as I thought it would be.



As for the keycaps in the picture they are a key set called Retro DSAs. They were from a group buy held many years ago. Sadly the only way to get them now is to purchase or trade for them second hand.

 
Thanks! And if you're interested in making your own custom keyboard, check out the Swillkb Plate & Case Builder and our custom keyboard example parts.

Realistic Mini Cannon Made with Parts from Big Blue Saw

From mini cannon tech Alex comes this wonderful 1/10 scale cannon. Modeled after 1841 6pdr field gun, this may be one of the most realistic minitature versions ever made.

Many of the parts of this masterwork of miniature munitions were waterjet cut by Big Blue Saw. You'll notice that the carriage and fittings are wood and steel. We made many of the steel parts. Oh, did I mention that it can actually fire? Check it out:

 

If you've decided that this would be a great Christmas present for you or someone you love, head over to the official website to order. But hurry, these are hand made one at a time.

 

Jay Doscher's Raspberry Pi Field Unit

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Jay Doscher told us about another great project he's built with help from Big Blue Saw. Read more about it here. You may remember his previous projects from this blog 1 2.

I’ve been working hard on a project that allows me to take a Raspberry Pi 2 into the wild outdoors. While there are many cases out there that work fine in a cabinet or on a desk, I couldn’t find one that would work outdoors. I became familiar with weatherproof enclosures when I started tinkering with my Solarbot a couple years ago, but I needed more than a small plastic box this time. This time around I wanted something that would support my Solar Robot 7 (which is live on Twitter here), a Raspberry Pi 2- powered solar tracker. More on that soon!

Read more about the RPFU at Jay's blog.

circuitBoards

Parts from Big Blue Saw:

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AluminumParts

Building the Open Source FarmBot with Big Blue Saw

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You may have heard of FarmBot, an open source robot for automatically growing and managing the lifecycle of plants. It turns out that the first FarmBots are being made with parts from Big Blue Saw. Here's what Rory Aronson of the FarmBot project had to say about Big Blue Saw:

At FarmBot.io, we’ve been fortunate to work with a fantastic water jet cutting service provider named Big Blue Saw. Big Blue Saw is attractive for us to use because they are an online-first service that really caters to their customer’s needs. On their website you can upload a .DXF file of your parts, choose your material and quantity, and receive an instant quote for free. If the price looks right, you can place the order right then and there, and your parts will arrive at your doorstep within a week or two!

 

farmbot-640

 

Here's the FarmBot in action. See if you can spot the waterjet cut aluminum parts.

You can keep up with the latest FarmBot developments on their blog, or follow the project on Twitter. They recently got FarmBot to plant its first seeds!

How Bite Force the BattleBot Was Built with Help From Big Blue Saw

 

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We recently got the following message from Aptyx Designs, currently the #3 seed and a semi-finalist in this season's BattleBots.

Want to see how our frame was built? We designed all of our aluminum unibody frame to be waterjet cut by Big Blue Saw! The frame is all 1/4", 3/8", and 1/2" 6061 aluminum plate. By designing the parts with interlocking puzzle tabs, there is a strong mechanical joint even before welding!

 

This method allows for super fast construction, accurate jigging for welding, and a strong mechanical joint by having the zig-zag weld area, and lots of filets for welding.

 

If you design parts, you can upload them to Big Blue Saw and get instant quotes, including the material costs, and see how your design affects the pricing! No need for sending out for quotes and waiting, they are super easy to work with.

 

After all of or parts were waterjet cut, we were able to do minimum fit up work, jig everything together, and get Applied Welding in Mountain View to weld everything up for us! Welding thick aluminum requires a very experienced shop to ensure proper penetration and minimal warping. Eddie Irlanda is our man for welding everything!


To learn more about designing assemblies for waterjet cutting, read our articles on construction techniques for use with waterjet cut parts.

 

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If you need custom parts for your robot, read more about how Big Blue Saw can turn  your ideas into real parts made of aluminum, steel, and more.

 

 

 

 

Royal E-Field Electric Motorcycle Built with Waterjet Cut Parts

wholebike

From Big Blue Saw customer Aaron comes the Royal E-field, an electric conversion of a 2005 Royal Enfield Bullet 500 motorcycle.

Aaron talks a little bit about how he got started using Big Blue Saw:

I transferred the drawing into a program called Inkscape, a freeware vector graphics program.  The program loaded easily and a 20-minute tutorial video was enough to get me started.

 shelves design

Aaron also has some great info on accurately bending 5052 aluminum using only hand tools. You'll note that he cut reliefs along the bend line (as described in our article on bending metal), bend at 90 degrees to the grain of the material, and also used a special waterjet cut jig  to make the corners the right radius.

bent lr

 How does it ride? Take a look at the videos below to see:

Custom DJ Controller Panel by TABS

We've been getting a lot of work for people creating custom audio components and DJ control panels. DJ Tech Tools user TABS created this excellent control panel using Big Blue Saw. He also wrote a nice review of Big Blue Saw's services.

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Our price for a part like this is approximately $25 each, with the price coming down to the $20 range if you order 10 or more.

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Big Blue Saw
4.9 stars - based on 32 reviews
Waterjet and Laser Cut Custom Parts.
Address for correspondence only:
3522 Ashford Dunwoody Rd NE #145
Atlanta, GA 30319
Phone: (678) WAY-SAW4 (678) 929-7294