Summary

This project is a compact and ultralight saw designed specifically for multi-day mountain hikes where every gram matters.
The handle is made from a 20 mm × 22 mm carbon tube (250 mm long), combined with two 3D-printed ABS end-caps that secure a standard 240 mm reciprocating-saw blade. The result is a strong, minimalistic, and reliable backcountry tool that weighs significantly less than any commercial folding saw.

This ultra-lightweight travel saw weighs approximately 70g. This is extremely light for a tool of this size.

!!!A blade-orientation key has been added to prevent the saw blade from rotating around its axis during use. Slot dimensions inside the carbon tube: 3 mm diameter, 4 mm depth.

Materials Needed:
— Carbon tube Ø 20 mm / 22 mm, length 250 mm. The length of the tube can be shorter (245-250mm).
— Two 3D-printed ABS end pieces
— Reciprocating saw blade 240 mm — WURTH RED LINE 1531L (2 pcs, code 1615153102)
— Paracord (< 1 m) for blade tension / retention loop

Assembly Instructions

Print both ABS parts and clean their inner channels.
Insert them into the carbon tube ends.
Slide the 240 mm blade into the slots and secure using the integrated locking features.
Tie a short piece of paracord to improve grip, add a wrist loop, or fix the blade during transport.

Print Settings

Printer Brand:

Bambu Lab

                                            Printer:                      
Bambu X1C
                                                                                Rafts:                      
No
                                                                                Supports:                      
No
                                                                                Resolution:                      
0.2mm
                                                                                Infill:                      
40-60%
                                                        
                        Notes:                     
The design focuses on minimalism and functionality for long-distance trekking.
ABS is recommended due to strength and temperature resistance, but other tough filaments can also work.
Blade fit is intentionally tight for maximum stability. Sand lightly if needed.