This study presents the design, development, and performance evaluation of a cost-effective, semi-automatic vertical hacksaw aimed at small-scale manufacturing workshops. Traditional manual cutting tools are limited by low precision and high labor intensity, while CNC or laser-based solutions are often cost-prohibitive. The proposed machine utilizes a compact vertical design, powered by a 0.5 HP single-phase AC motor and controlled by a speed regulation unit. The mechanical drive system uses a crank-slider mechanism to convert rotary motion into smooth reciprocating cutting motion. Finite Element Analysis (FEA) was performed using ANSYS to assess stress distribution, deformation, and dynamic behavior of critical components. Experimental testing was conducted on aluminum, PVC, and wood samples. Key parameters included cutting time, surface quality, dimensional accuracy, and energy consumption. Results demonstrate that the developed machine consistently outperforms conventional manual hacksaws, achieving average cutting times of 4.2 s for wood, 13.4 s for PVC, and 30.8 s for aluminum, with burr-free surface finishes across all materials. The system operated within safe mechanical limits and generated low operational noise (62–68 dB). These findings confirm the machine’s suitability as a reliable, low-cost alternative for educational labs, prototyping environments, and small-scale workshops, offering improved productivity, material utilization, and operator safety.