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

Chris Einerson of Postmark USA wrote in to tell us about how they use waterjet cut parts from Big Blue Saw to save time and money and deliver a finished custom project in less than 2 weeks.
We have developed an industrial turnkey solution for high speed inkjet printers used in the mailing industry. Our inkjet printer can print at speeds up to 100,000 pieces of mail per hour and are usually used for printing the address and barcode for direct mail applications. Other applications outside of mailing for our industrial print heads could be printing barcodes, lot numbers, or serialization. 
Postmark has developed a modular mounting system that allows our customers to order custom mounting solutions which can be tailored to any piece of equipment. The mounting system we developed uses a handful of waterjet parts to make an industrial linear slide with height adjustment that runs across a piece of aluminum profile. This slide allows for easy position adjustment of the single pass print head. The 1" thick waterjet brackets bolt down to a conveyor system and allow for the entire bridge mechanism to be hinged up for cleaning the bottom of the cartridges that are installed in the printhead.
The main reason for choosing waterjet on this project was the timeframe and cost. After looking online for quick turnaround vendors I found your website. After doing some cost analysis we determined that waterjet would be very fast and the online quoting tool was very helpful.
We designed the product around using water jet for the majority of the parts and we were able to make small adjustments in the design and get a quote on the fly. This helped us quickly design the system and we were able to have a system ready to ship to our customer within 2 weeks.

Recently you may have seen FarmBot mentioned on Hacker News, Smithsonian, Farm Forum,  or The Verge. We mentioned FarmBot here in October of last  year. 

Rory Aronson, founder of FarmBot says:

These waterjet cut plates are one of the main structural elements of FarmBot - humanity's open-source CNC farming machine. Combined with aluminum extrusions, these plates are used to mount motors, wheels, and 3D printed components of all sorts to form FarmBot's tracks, gantry, cross-slide, and z-axis sub-assemblies. If you're interested in building a FarmBot of your own, go to to download the latest .DXF file, then place an order from Big Blue Saw for a set of plates made from 0.1875" 6061 aluminum, and follow the build instructions available at the FarmBot website!

We've also put the June 2016 version of the DXF file on our examples page.

We recently improved on the zoolophone by creating a laser cut base to mount the pieces to and re-cutting the pieces to add features missed the first time. We also added 4 new pieces which play a chord when struck!

Watch the video below to see how it was done. and to hear this new Zoolophone. I especially love hearing the chord giraffes.

Special thanks to Steve Sparks for the assistance with recording and performance.


Save Monday, July 18 through Wednesday, July 20, 2016


From Monday, July 18 through Wednesday, July 20, Big Blue Saw is having a sale on custom parts made from YOUR designs. All parts waterjet cut from 1/4 inch thick aluminum 6061 and ordered online will automatically receive a quantity discount. If you've got designs you would like to turn into a real metal parts, now is the time.

Order Now

About Aluminum 6061

Aluminum 6061 is a strong, weldable, corrosion resistant alloy. It's commonly found in where high strength and light weight is needed, and was used to make the frame of the Space Shuttle  as well as the armor and frame of the BattleBot Bite Force, sponsored and waterjet cut by Big Blue Saw. For the technically minded, the aluminum used in the sale will be the typical T6 hardness, which provides a good strength without being too brittle.

Aluminum 6061-T6 and waterjet cutting go together well. The low temperatures used in waterjet cutting mean that the heat treatment of the metal will not be affected and it will maintain its strength even after it is cut.

How You Can Save

To take advantage of the sale, just place your order online July 18-20 through our online quoting system. Orders placed online will automatically receive the quantity discount.

Have a look at our butterfly example, for instance. Normally in quantity 1, this part will cost you $92.10. However, during the sale it will run you just $11.30 for quantity 1, a savings of 88%.

Or look at this multi-part keyboard case. Normally when cut from 1/4 inch thick aluminum 6061, we charge $103.40 per set. During the sale, it can be yours for just $56.20, a savings of $47.20.

This logo design normally runs $92.10 when made from 1/4 inch thick aluminum 6061.  During the sale, it's just $24.30, or 74% off!

Get started by uploading your design to our online quoting and ordering system now.

Summer has begun. It's warm out there. You reach for your favorite beverage of choice, but alas! it's in a bottle and you have no opener. At Big Blue Saw, we've got you covered. We recently tried out a few different bottle opener designs to see which worked best.

There are two main types of openers we've seen: through-hole and side mounted.

The through hole type should be made from mateiral 0.06 inches thickness or thinner. Some people will grind down the lower lip of the opener to make it thinner.

Side mounted can be of nearly any thickness. These are more common and are typically seen on waterjet cut multi tools. One customer of ours even incorporated an opener into a sports trophy.

We created a couple designs with different sizes to test which shape worked the best as an opener. Here's the outline of each test design.

Through hole bottle openers


Side mount bottle openers


We waterjet cut the side mount opener from 0.125 inch thick stainless steel 304. We needed a thinner material for the through-hole piece: 0.06 inches thick.

The Results

Most of these designs worked reasonably well as bottle openers. The key to getting a working bottle opener seems to be making sure that the prying end and pivot end are close enough together. Some of the tested openers were a little too large, like the biggest of the through hole openers.

I also noticed that the farther away the pry end was from the pivot end, the less the cap was bent before being removed. The smallest of the crescent shaped openers bent the bottle cap quite a bit before removing it. In contrast, the largest working through hole opener barely made any perceptible change to the cap.

Through Hole Openers

Of the through hole designs I tried, the middle two flattened circles and the trapezoidal design worked best. The largest shape fit completely over the top of the cap, giving no leverage. The smallest worked, but you needed to be a little more precise when aligning the pry end with the edge of the cap.

Side Mount Openers

I tried a bigger variety of side mount openers, so let's break them down by type.

The Big Opener

At the very end of the opener you can see the Big Opener. I thought that this would be too big, but the spacing between the pryer and the pivot was just right to remove the cap without too much bending.

The Crescent Openers

Next to the Big Opener are crescent shaped openers in 4 different sizes. These all worked well. The smallest of the crescent openers is the best choice for a compact remover, though it bends the cap significantly before removing it.

The Pointy Openers

Next to the crescent are the 4 pointy openers. All 4 worked reasonably well. I can't really recommend this shape, however, as the pivot end is quite sharp. You don't want this around to cut your fingers when reaching into your pocket or tool drawer.

The Rocker Openers

I thought that this shape had great potential, so I tried it in 3 different sizes. At first look, it seems similar to the Big Opener. But if you try to use it the same way, it won't work. This opener is meant to be used in the opposite direction. With the Big Opener, you start the tool in a horizontal position and the the pry end is located toward the inside of the tool. In contrast, with the rocker openers, the tool starts in a vertical position as you maneuver the sharp pry end under the cap, then rock against the rounded end.

I had high hopes for this opener, as it's included on the fishbone multitool. However, the pry end kept slipping loose from under the bottle cap. I can't recommend this design without some further refinement. The pry end needs a tooth to dig in the underside of the cap, or possibly a steeper rake angle to really create solid contact.

Take a look at this video showing some of the openers in action to get an idea of how well they work.


We mentioned multi-tools and trophies as having an opener feature. Buy why restrict yourself to these? You could add an opener shape to any of these:


Download the Through Hole Opener DXF File

Download the Side Mount Opener DXF File