Batavia Maxxsaw

  • 2016

  • Product
    Hardware and Building

Designed By:

Commissioned By:

Batavia GmbH

Designed In:


The Batavia Maxxsaw is the latest generation mini plunge saw model in the Batavia range. With refined aesthetics, numerous functional additions, improved ergonomics and safety, the Maxxsaw model brings a new level of premium tool to the Batavia range.

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  • The Batavia Maxxsaw offers a simplified guard release with built in safety features to ensure the process is faster and safer. The guard is released by depressing a protected button, that can only be accessed by the on-board hex key. This allows the guard to pivot open and expose the cutting blade ready for replacement, inspection or cleaning. No other tool is required to open the guard. For increased safety, when the guard is opened, power to the trigger is disabled by way of sensor switches in the head of the tool. When finished, the guard can be closed and is automatically secured, ready for next use.

  • Laser guided saw products have existing in the marketplace for many years. In many cases the laser is a self-contained battery operated device that is simply attached to the exterior housing of the product. They require their own unique power supply (a battery) and therefore would require multiple battery changes during their life. The Batavia Maxxsaw was developed with an integrated mains power laser guide. This allows a consistent product aesthetic, as the unit is now integrated and not “tacked on” aftermarket product, and the user will never have to change a battery.

  • Mini-plunge saws normally require a hex key that is typically found on the cord flex at the rear end of the product. This is a convention that has been carried on for many years, simply as the standard solution. The downside is that the tool can interfere with the surrounding work environment. To avoid these issues, we integrated the hex key into the head of the Maxxsaw. This was achieved with smart component packaging to avoid the internal mechanisms, and provides for a much cleaner product aesthetic. The hex key is secured in place by the outer housing.

  • The overload warning light on mini-plunge saws is typically located at the rear of the product near the power cord and PCB as this is the most cost effective location. However, during usage the operator's eyes are focused on the head of the product and an active overload warning light can frequently go unnoticed, potentially leading to product failure. To improve this, we moved the overload warning light to the front of the Maxxsaw where we were able to clearly improve visibility to help reduce the chance of critical product failure.

    Safety standards dictate a three step process to start a mini-plunge saw. Guard release, then trigger release, then switch actuation to start the tool and begin cutting. The process is purposefully difficult to prevent accidental operation and improve safety. For the Maxxsaw, we implemented a central, head mounted thumb operated guard release, so the user could release the guard whilst still maintaining a firm grip on the tool. The user can then reposition the thumb, followed by operation of the two stage lock out switch with their index finger. By operating the tool this way it allows the user a free hand to support themselves and provides for ambidextrous single-handed operation.