objective of the present study was to determine the effect of ergonomically designed handsaw with different orientation on the upper extremity muscles activity during the wood cutting process through experimental and objective assessments. Three ergonomically designed handles with different holding positions were designed using 3D printer. The ergonomic effectiveness of the proposed design was evaluated, and the results were compared with a standard handsaw. For objective evaluation, ten male participants were asked to cut the wooden piece using three modified handsaw and standard handsaw. Surface electromyography (sEMG) system was used to measure the muscle activity on arms and shoulder muscle. Subjective analysis was carried out through a questionnaire survey using Borg’s RPE scale. The results identified that handsaw handle with different handle orientation would increase the biomechanical load acting on the selected muscle. Handle with the curved holding region and less wrist orientation (0–10°) can reduce the muscle loading on the arm and shoulders.