Optimal Design was engaged to help Dremel take the concept of the mini circular saw to a new level. This power tool had to be durable, easy to use, and light on the pocket as well as in the hands. One of the innovations was the removal of the usually cumbersome lower guard (this saw uses an abrasive wheel instead of a saw blade) and improves the line of site to the work piece and blade. Our team worked in collaboration with Dremel to develop the final concept prior to detailed engineering. In the engineering phase, we designed all of the components to be fully manufacturable while addressing details such as airflow, weight, and manufacturing cost. We also provided functional prototypes that were used for performance testing. Together, Optimal Design and Dremel collaborated on a great new tool with exceptional versatility.