I wanted a small workbench that was easy to move around and store, but still rigid enough for proper woodworking and workholding.
The result is this mini portable workbench, built mainly from plywood and using a torsion-box construction to keep the weight down while maintaining a stiff, flat working surface.
The finished bench weighs approximately 4.9 kg / 10.8 lb, so it is easy to pick up and move around the workshop, take outside, or store away when it isn’t being used.
Watch the build
In the video below I show the complete build, from the Fusion 360 design and CNC machining through to assembly and some of the ways I use the finished bench.
YouTube video:
https://youtu.be/TgCTjMzW1vQ
The design
The bench is based around a lightweight torsion-box structure made from plywood.
The internal frame creates a surprisingly rigid structure without requiring thick or particularly heavy material. It also helps keep the work surface flat.
The main worktop is made from 18 mm plywood and has:
- 20 mm dog holes
- 96 mm MFT-style spacing
- Side openings for clamps
- Handhold-style openings for carrying
- A compact footprint suitable for bench-top or portable use
The openings around the sides can be used either to clamp the workbench itself to another table or to clamp workpieces directly to the bench.
You don’t need a CNC
I used my SainSmart Genmitsu PROVerXL 4×4 CNC router to cut the components because it makes positioning the dog holes and cutting the repeated openings quick and accurate.
However, there is nothing about the basic design that requires a CNC.
The same bench could be made using conventional woodworking tools such as a track saw, router, jigsaw and drill.
If you don’t need the MFT-style dog holes, there is also an even simpler option.
The 12 mm plywood skin on top of the torsion box can itself be used as the work surface, giving you a lighter bench while retaining the useful side clamping openings.
Workholding
The 20 mm holes allow the bench to be used with a wide range of standard and 3D-printed bench dogs and accessories.
I use them for:
- Supporting and locating workpieces
- Clamping material against dogs
- Positioning track-saw rails
- 3D-printed workholding accessories
- Expanding bench dogs
One of my favourite designs is a 3D-printed expanding bench dog. Rather than relying on a very precise interference fit, the dog expands inside the hole to lock itself securely in place.
For fixed-diameter bench dogs, the hole size is more critical. I recommend making a slightly undersize test hole first and gradually increasing the diameter until you achieve the fit you want.
Fusion 360 design file
I’ve made the Fusion 360 design file used for this project available as a digital download.
This is the editable design file rather than a full set of woodworking plans, so you can inspect the model, change dimensions or adapt the design to suit your own requirements.
Download the Fusion 360 design file – £1.99:
https://buymeacoffee.com/techydiy/e/572974
The YouTube video above shows the complete construction process and can be used alongside the design file as a build reference.
CNC router used
I cut the plywood components using the:
SainSmart Genmitsu PROVerXL 4×4 CNC Router
The link above may be an affiliate link. If you purchase through it, I may receive a small commission at no additional cost to you. This helps support Techydiy and future projects.
Final thoughts
The main aim of this project was to make something small and lightweight without turning it into a toy.
The torsion-box construction gives it the stiffness needed for real workholding, while the dog holes and side openings make it considerably more versatile than a simple portable table.
It has already proved particularly useful for jobs where I don’t want—or simply don’t have room for—a full-size workbench.