Irwin |
Jack Handsaw

 

Design | New Product Development
Industry: Power & Hand Tools
 

The Challenge

Irwin was experiencing a decline in sales and market share with their entry-level handsaw range. They needed a redesign that would:

  • Refresh the product’s aesthetics.

  • Improve ergonomics and user comfort.

  • Remain cost-effective to manufacture.

  • Work across multiple saw variants.

 

 

The Solution

We developed a new handle design with:

  • Improved ergonomics for better comfort and usability.

  • Refreshed aesthetics to appeal to modern users.

  • Two-shot moulding with TPE rubber – adding premium comfort and grip to an entry-level product, while maintaining low manufacturing costs.

The design was scalable, allowing it to be applied across the wider saw range.

 

The Results

  • The redesigned Irwin handsaw was launched to strong market success.

  • The saw has remained in production for over 10 years, proving its long-term appeal and durability.

  • The project reinforced Irwin’s market position and demonstrated the value of investing in thoughtful product design.