Capstone Project: Portable Sawdust Collection System

Voted “Best Presentation” Spring 2025, Madison College Mechanical Design Technology Program

For our Capstone project, we were tasked with coming up with a unique product that would meet a need in the market. My team decided to design a portable, compact and easy to use sawdust vacuum. Other solutions on the market are either bulky and expensive or corded and aren’t easy to maneuver in work stations.

The Problem:

Sawdust generated while woodworking can cause safety issues, health concerns, and operational challenges. Depending on the workshop, a large sawdust collection system can be expensive and unnecessary. Also, ShopVac and other vacuums can be bulky and can’t be used at the same time as another machine. 


Conceptual Design

Shell and Interior Assemblies

3D Renderings of Exterior

Final Design


Product Details

Shell Assembly:

  • Protective aluminum main body 

  • Easily detachable dust catcher 

  • Removable lid for maintenance 

  • Handle for carrying 

The Solution:

Our product is a compact, fun, and easy-to-use sawdust vacuum. The DustMate is able to collect dust as you use other tools. The compact design allows it to be out of the way but still effective. The flexible hose helps reach any position while you work, collecting sawdust as it is being made. 

Prototyping

Exploded Views

Full Assembly

Motor and Fan Mount

PowerAssembly:

  • 18 to 20 Volt Motor

  • 18 Volt Battery 

  • Governor

Fan Assembly

Assembled Functional Product

Fan Mount Assembly:

  • Centrifugal fan design

  • Improve suction compared to an axial fan

  • Compact design

  • Mounts the motor


Cost Breakdown

Purchased Parts 

Motor = $31.67 

Motor governor = $9.99 

Battery adapter = $17.89 

Hose = $19.99 

Fasteners = $2.52 

Heat Sinks = $1.45 

Wiring = $1.00 

Wiring connectors = $0.06 

Total = $84.57 

3D Printed Parts 

3D printed parts 

Cyclone = $48.77 

Fan mount = $20.27 

Fan = $21.16 

Dust catcher = $5.82 

Hook connection = $1.11 

Separator = $1.05 

Lid = $2.23 

Handle = $0.15 

Gaskets = $6.65 

Cyclone connection = $8.90 

Total = $116.11 

Prototype Cost

$200.68 

MSRP = $60-$70

Final Design Part Prints

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