Big  Blue Saw


Starting April 18, 2022, quoting and ordering will begin moving from Big Blue Saw to the Xometry website. You'll continue to be able to get fast service and instant quotes, in addition addition to a whole host of new materials and manufacturing processes!

General Updates

There has never been a better time to get started using Big Blue Saw to turn your designs into real parts. Starting Monday, October 16, Big Blue Saw is offering discounts on our waterjet cutting service. During the sale, parts made from 0.1875 inch thick (that's 316 or about 4.8 mm) aluminum alloy 6061 will automatically receive a quantity discount. Just place your order on our website to receive the discounted rate. Orders as small as 1 part will automatically receive the quantity 10 price, saving you as much as 75% off.

Image © Steve Brown Photography CC-BY-SA-3.0

These parts are cut using a waterjet cutting machine, a system which uses a high pressure stream of water and garnet particles controlled by a computer to manufacture your parts from solid sheets of material. Big Blue Saw uses waterjet cutting to make parts for everyone from the garage inventor to the biggest corporations. Here are just a few of the things we've made:

3D printer frames Head gaskets
Animal cages Heat sinks
Arcade game joystick mounts Industrial controls
Bicycle dropouts Industrial HVAC equipment
Business cards Kite fabric templates
Computer casemods Knife blanks
Control panels Lighting fixtures
Costumes Machining fixtures
Dashboard panels for airplanes and airplane simulators Motor mounting brackets
Dashboard panels for cars Motorcycle dogbones
  Movie props
Desk nameplates Nixie clocks
Drain covers Oil pipelines
Electronic bus bars Painting jigs
Electronics enclosures Prop replicas
Fighting robot frames Rope belaying devices
Fine art Signs
Fireworks control panels Sporting goods
Fixtures for science experiments Stencils
“Free energy” machines Test tube racks
Gears Trophies
Go kart frames Ventilation registers
Ground straps Video monitor brackets
Guitar capos Wedding cake toppers
Guitar frames Wheels
Guitar pick guards Windmill contactors


If you're ready to have your designs turned into real parts, this sale is a great time to get started. Hurry, remember that the sale ends on Wednesday, October 18. Upload your parts now to our online quoting and ordering system.

Starting Monday, October 16, and running through Wednesday, October 18, Big Blue Saw will be having a sale on custom waterjet cut aluminum parts made from your designs. This sale is on aluminum alloy 6061 in 3/16 inch thickness (0.1875" or about 4.8 mm). All orders placed online for this material during the sale will automatically receive a quantity discount.

Upload your parts to our online quoting system now to get them ready for the sale.

Keep watching the blog for more updates. You can also follow us on Facebook, Twitter, LinkedIn, or, best of all, join our mailing list to receive updates about sales and more.


You've been asking for it, and now it's here. You can now order custom waterjet cut aluminum 7075 parts directly from our website.

I used this material in my robot Flipper for Robot Battles this year. You can see it in the photo above: the claws on the robot are aluminum 7075 in 3/8 inch thickness. It held up spectacularly when lifting opponents, falling off the stage, and being attacked by other robots. Flipper went on to win the final rumble in the 12 pound division.

Aluminum 7075 offers greater tensile strength than 6061 or 5052 alloys, so it's fantastic for any application where the parts will be undergoing mechanical stress. On the flip side, it's not weldable like 5052 or 6061, doesn't have the formability of 5052, and is more prone to corrosion in harsh chemical environments. But if you're looking for an aluminum with an ultimate tensile strength that's 85% higher than alloy 6061, 7075 is the way to go.

Order your parts in aluminum 7075 from our website today!



Wikispeed is an open source road legal car, for commuting and racing. They take the idea of open source seriously and everyone is invited to collaborate.

Above you can see Car #007, built for testing new part versions. Many parts on this car were waterjet cut by Big Blue Saw: the front pedal plate, the suspension corners, pieces in the engine module and interior, and more.

Being open source, Wikispeed collaborators make use of a variety of CAD software, based on the preference of the individual designer. The most used package is Geomagic, with some members preferring SolidWorks, FreeCAD, or AutoDesk Fusion. The design files are available for free download

This video shows the Wikispeed SGT01 100 MPG car.

Joe Justice of Wikispeed sent us a few photos of the Wikispeed parts made by Big Blue Saw.
Here is a stack of steering knuckles waterjet cut from aluminum 6061, 0.25 inches thick.

Waterjet cut suspension A-arms. These were waterjet cut from 0.25 inch thick aluminum 6061.

The latest suspension knuckle version in a subassembly. 0.5 inch thick aluminum.


Prototype windshield and wiper frame, waterjet cut from 0.25 inch thick aluminum.

In this video, Joe Justice of the Wikispeed project discusses why the easy ordering and quick turnaround of Big Blue Saw is useful for the an open source car design.

Check out Wikispeed's YouTube channel for the latest updates and videos of the car in action.

Brogue Motorcycles modifies motorcycles and builds custom bikes from scratch. But they wanted to reach a wider audience for their mechanical art, so they designed and created a product they could sell to customers: a lighting kit for the Suzuku TU250 motorcycle. Mike Schartz of Brogue tells me that this bike is a great choice for modifications due to its low cost and a large base of after-market accessories.

Brogue Motorcycles does their cutting, grinding, welding, soldering, bending, fiberglass, upholstery and powder coating in house. They were also able to use their experience in aviation and sheet metal repair to bring this product to market. They used custom waterjet cut parts from Big Blue Saw to speed up the creation process at a reasonable price. 



Brogue Motorcycles chose a combination of aluminum and stainless steel materials based on their weldability, formability, and strength. The waterjet cut parts were designed in AutoCAD.