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

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When it comes to custom parts for musical instruments, Big Blue Saw is the top choice for the instrument makers and musicians in the know. Over the years, we've made specialized guitar capos, sitar bridges, replacement accordion parts, and much more.

I've never seen an entire musical instrument using waterjet cut parts, though, so I set out to create one. After considering several possibilities, I decided to build a simple thumb piano. A thumb piano consists of a set of tine each tuned to a different note. When plucked, the sound of each tine resonates in a chamber to amplify the sound.

I started by using the free xylophone bar length calculator from Windworld. I input the longest bar length of 4 inches, and the calculator spit out the lengths of all the bars such that they would form an octave plus one higher note. The shortest bar was 2.83 inches accoding to the calculator. From there it was easy to design a "comb" with the various tines.


Next, I needed a resonating chamber. The best way to do this with waterjet cut parts is via the stacking technique, described in its own article. I designed a plain flat piece for the bottom, pieces with cavities for the middle layers, and a top with a resonating hole for the sound. I added holes so that I could bolt all of the pieces together, including the comb. Finally, I added two more small spacer pieces so that the comb could rest slightly elevated from the top of the resonator.


With this design, I could use just about any material and thickness that would be stiff enough for the tines to vibrate. I chose 1/8" thick aluminum 6061 alloy as it's relatively inexpensive and this was just a prototype instrument, after all.

After the parts were waterjet cut, I bolted them together using #10-24 machine screws.

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Now it was time to play. How does it sound? Check out the video below.

OK, it's a little out of tune. This is partly due to the calculator I used being designed for free floating xylophone keys, not tines which are all connected on one end. The higher notes sound more musical than the lower notes, so if I had to do it again, I'd start with the longest tine being around 3 inches. I would also consider using more and thicker bolts to hold the case together, as I noticed sublte rattling of the layers when the notes are struck. Plucking one note can cause the others to ring a little bit, so I would change the design to isolate the notes a little better, perhaps by using multiple combs. Finally, brass might make a better choice than aluminum for the material, as it's a more "musical" metal.

If you've got any more ideas for improving this thumb piano, let me know in the comments section or by e-mailing


This weekend, don't miss the second appearance of Bite Force from Aptyx Designs, sponsored by Big Blue Saw.

Tune in to BattleBots this coming Sunday, July 12 at 9pm on ABC Television Network when Bite Force faces off against HyperShock in the round of 16!

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The reviews prove it: our customers love us. We've got a 5 star rating on Big Blue Saw's Google Plus page.

Check out more Big Blue Saw reviews and testimonials.


Big Blue Saw is proud to announce we're sponsoring a robot created by Paul Ventimiglia and his new team, Aptyx Designs, for the BattleBots robot fighting competition.

As a sponsor, Big Blue Saw waterjet cut the robot's  aluminum frame based on the CAD drawings provided to us by Aptyx Designs.

The 2015 BattleBots competition will be televised starting on June 21. Until then everything remains TOP SECRET! We cannot even reveal the name of Paul's robot! We will say that we think it's pretty amazing

But here is a EXCLUSIVE sneak peek at the design of some of the waterjet cut 3/8" thick aluminum parts you'll see in this new powerful fighting robot:

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How do those pieces fit together to make a robot? If you've read our article on tab and slot construction, you should have a pretty good idea. Or you can read more articles about how to design parts for waterjet cutting.


We're happy to announce 3 great new options for white plastic. Many loyal Big Blue Saw customers have been searching for better options for white keyboard plates, enclosures, control panels and the like.

First up: we are now offering white acetal plastic in 0.03 and 0.062 inch thicknesses. Acetal is a tough, durable material for machine parts, bearings, washers, and the like. We also offer acetal in black and in a variety of other thicknesses.

Next, we are pleased to offer white ABS plastic in 0.06 inch thickness. ABS is also tough, but less suited for wearing applications than acetal. It's also easier to glue, form and shape, and has better chemical resistance than acetal.

All of these new options come in white. But is white really white? Listen to the sonorous voice of poet Ken Nordine answer these questions far better than I ever could.

As always, if you don't see the material you need for your project in our online quoting system, please contact us and let us know what you're looking for!