Festool developers Matthias Kübeler and Andreas Sdrzallek

TechTalk: A saw built for life

From prototype to series production: In this interview, we get exclusive, behind-the-scenes insight from the makers of the new CSC SYS 50.

There's no doubt that the new CSC SYS 50 is a saw built for life. The CSC is not just an extremely durable purchase for users, for our employee Dominic Ender, who was writing his thesis at Festool when the development phase started, constructing a mobile bench-mounted circular saw has been his life's work. He looks back on the process – together with Product Manager Wolfgang Reines – very proudly.

Two bright minds

Dominic Ender (left in image) and Wolfgang Reines (right in image) were key figures in the development of the CSC SYS 50 mobile bench-mounted table saw. We dive into the process in a Q&A session and look back together on an exciting development phase.

How did you come up with the idea of creating a mobile and compact bench-mounted circular saw?

Dominic Ender: I was looking for a partner to collaborate with on my thesis to become a Product Designer. As a trained joiner, of course, I was very familiar with Festool and so I decided to get in contact. In our first interview, I presented three concrete ideas and I asked directly whether there were any topics at Festool currently, which would be appropriate for a thesis. There was a lot of focus on the bench-mounted circular saw. So, we got started.

Wolfgang Reines: At Festool, there are various ways to generate and pursue ideas. The idea for our Systainer saw originally came from one of our test customers. The idea of simply building a circular saw in a Systainer to, for example, allow sawing of infill panels at the construction site, was not one we can simply take and translate one-to-one. We need to consider the applicable norms before implementation. So, we like to use thesis works to explore this, since they can take an idea without limits, explore and make it feasible. The graduands look at it without "Festool glasses" and let their ideas run free. So, we were also able to tempt Dominic on board for this idea, and he grabbed the chance.

Was the concept always going to be a cordless product?

ENG: I was constantly refining the cornerstones of my concept during the design phase, in consultations with craftspeople. At that time – so 2014/15 – I always got the feedback that "a cordless tool would be nice", but a corded tool was preferred. So the original concept was actually cabled. It was only during the development that the customers' preference switched to cordless. We constantly adapted the product to the needs of our customers.

How long did it take from the first idea until you made the prototypes?

ENG: For my thesis – which took six months – I developed a detailed concept and built a design model. It looked like a product and had moving parts to simulate and test the operability, but didn't actually saw. We took this model to our craftspeople in many countries to explore the overall concept for its market viability and acceptance.

WR: It took several years to bring the initial idea to market release. Of course, we weren't working non-stop on the concept during this time. After the first phase of the thesis, which was six months, we had a break. We used this to firm up the overall scope of the product and prepare for an official project launch. In the end, it's always the feasibility study that decides whether a project launches or not. After the project was approved, we formed a team from various technical areas like construction, quality assurance, plant for assembly planning, purchasing and many more. Only after all that, can a project really begin. This development phase lasts around three to four years for us, depending on the project size.

Dominic, do you have a background in trade or crafts?

ENG: I trained as a carpenter/joiner. Since I was young, I've always been interested in making things with my hands.

How did you identify the need for this kind of saw?

ENG: The need for a compact, lightweight and precise bench-mounted circular saw has been there fore a long time. The market for mobile bench-mounted circular saws for construction sites is huge. Festool even already had products for this in its portfolio. But the approach of the CSC SYS 50 is radically different and innovative – this tool provides a variety of solutions, is highly precise and all in a compact space.

WR: The requirements have mostly changed for interior finishing. 30 years ago, I was still installing many wood floors with my underfloor trimming saw. But the wood floor market has completely vanished in recent years. These days, we fit lots of prefabricated components, so you only need a saw to make the adjustments. You don't want to be lugging around a heavy bench-mounted circular saw for this and, if you have to, you can do the work with a jigsaw or a portable circular saw. We wanted to change that. We recognised the need for a compact and precise construction-site bench-mounted circular saw early on.

What are the differences between the prototypes and the final product?

ENG: The original concept I developed was based on the space of a Size 3 Systainer. I was able to meet all the requirements, albeit with some compromise, in this compact space. During the development of the saw, the concept and the requirements for cutting height were adjusted again and, today, the saw fits in the Systainer Size 5 horizontally – we chose the larger space to aid a larger saw blade.

"The approach of the CSC SYS 50 is radically different and innovative – this tool provides a variety of solutions, is highly precise and all in a compact space."

Dominic Ender, Product and Innovation Manager at Festool

The CSC SYS 50 can do so much in such a small space – what were the biggest challenges during construction?

WR: I'm sure you mean the difference between the model for the thesis and the final product. Some things changed compared to the model, and others didn't – the concept of building a saw in a Systainer didn't change at all. Otherwise we'd have had to rethink a lot and adapt to the requirements. The limited space was actually a big challenge. Step motors for the electrical adjustment needed to fit in the tightest space. That sort of thing wasn't in the model, we only imagined it. We also had a slide in the model. However, it was a big challenge to be able to produce this so it was lightweight, 3D-adjustable and yet precise. We also showed a display briefly but it was in no way fully designed. That was a pretty big learning curve for us. There were many challenges, but we'd never have time to describe them all here.

Were there reference products or comparable products on the market? What makes the CSC SYS 50 stand out from competitor products?

ENG: Actually there wasn't, and still isn't, anything comparable on the market. A mobile bench-mounted circular saw with electrical adjustment, a sliding table promising such precision and an operation concept which offers absolute repetition accuracy – it's unique. Pair that with the convenience of creating and saving favourites using the Work App and we've created a new class of tool, the "Mobile bench-mounted circular saws".

How did you involve the customers in the development?

ENG: I was in regular discussions with craftspeople right from the early phases of my design. I travelled all over Germany; first with my initial idea, then with early drawings, wooden models and finally my design model. And always with the aim of discovering people's needs and to test whether the concept was actually solving the challenges the craftspeople described to me. When I finished my thesis, we branched out and consulted internationally before and during the technical development.

WR: During the development phase, we involved the customer at various points in the project. We actually do travel to other countries with prototypes and test various functions.

What are its advantages compared to a regular bench-mounted circular saw?

ENG: The Systainer saw is a fully-fledged bench-mounted circular saw with all the functionalities you need for everyday. But thanks to its small size, its very different from the stationary bench-mounted circular saws which are usually used in the workshop.

How important was the weight during development and what measures did you take to not only make the machine as compact as possible, but also lightweight too?

WR: The weight is, of course, very important. We also had to keep this in the back of our minds when choosing the materials for the individual components. But in the end, the function was always our priority, as well as choosing the right materials to ensure robustness. For that reason, we didn't quite hit our weight target of less than 20 kg. But that actually has an advantage, since the machine is therefore more stable when sawing larger components.

The final question goes to Dominic: What grade did you get for your thesis?

ENG: I got fantastic feedback from the University. The exam committee gave my work a 1.0 in the end (equivalent to a first-class). That was both a great surprise and very satisfying for me, because it was the most challenging piece of work I'd ever done up to that point. But in the end, it's much more significant that my thesis actually led to what I do today, as Innovation and Product Manager at Festool.