What do the large companies use to make knives?

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Dec 29, 2010
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What equipment do companies like Gerber, SOG, etc.. use to produce their knives?

I'm assuming some type of CNC machinery but are the blades done that was also? Does a human ever touch the knife except for assembly?

Is there anywhere to see this process online? Thanks....
 
Magic, and gnomes, and millions of dollars in machinery...

In reality, a lot of different machines.
Presses, grinders, buffers, mills, dozens of different machines, depending on the process.
 
You can catch a few different episodes of "How It's Made" and "Factory Made". They've covered several different knives. A lot of punches, presses, and tools we can't afford involved in the production. That, and a long haired hippie fly fishing in Switzerland.

Check the links on the side.
http://www.youtube.com/results?search_query=how+it's+made+knife&aq=f

+1

See if you can find that episode on "How It's Made". They give a start to finish on a nice Case pocketknife.
 
This is an interesting question. It is a subject I've been interested in for years. I'm no expert, but I've picked up a few things I'll share.

Blades and other components (such as liners etc) that lend themselves to it are punched out or fine blanked. These would be higher volume applications. You can frequently recognize stamped parts because they have a bit of a rounded over edge on the side facing the female part of the die. The sheared edge is generally dressed up some, frequently manually. I think some larger blades may even still be drop forged in closed dies. The Buck 119 perhaps?

Lower volume applications that don't justify a tool and also high end knives where distortion from stamping would be unacceptable are frequently laser cut or waterjet.

I don't think there are a lot of manually ground bevels these days except for custom and semi custom knives. Knives like Dozier and Reeves are still hand ground, but most knives (such as Spiderco and Buck) are mostly CNC ground. There are some old automatic blade grinders that are not CNC controlled that are still used, I expect they're probably controlled with cams and/or hydraulic feed, similar to an old B&S automatic screw machine. Some grind both side of the blade at the same time, smaller setups may only grind one side at a time. Not all are ground, some are milled with large inserted carbide face mills. These can be two axis machines, three, four and even five axis.

Case knives are still largely handbuilt (with stamped components) in an old style of making things, and their old knife designs dictate this approach. Lots of manual grinding, polishing, riveting. A $40 Case may have more hand work in it than a $400 Sebenza, which is largely CNC machined (Chris is a machinist, so there you go). The Sebenza is a much nicer knife though. "Hand made" does not necessarily mean "better". Like anything else, it depends on how its done and the skill of the hands. A well machined and hand fit pocket knife is going to be about as close to perfect as you're going to get.

Heat treat on an industrial scale can be in batches (electric and gas fired ovens and fluidized beds) or in continuous production with conveyor belts and ovens or induction heaters. I think some cheap knives may be stamped and ground of prehardened strip. (HRC low 50's and below)

Finishing can be done automatically in vibratory finishing machines (again, Chris Reeves) or on large loaded buffing wheels (Case).

This is a cool subject. I hope others will chime in here.
 
Mike Snody was selling a large, old auto blade grinder not long ago. It was a cool machine. You may be able to find the pics if you go searching for the thread.

Before CNC machining was common, die sinking pantographs were often used to cut blanks from a design. Usually the design is bigger by ratio than the blanks cut, for a smoother product with better detail.

I want to hear more, too. Interesting stuff, Nathan.
 
I can't speak for any of the large volume production companies but I do know a little about CRK (Chris Reeve Knives)...

At Chris' shop, the blades start at the water-jet facility to create the rough blade blanks. They then go through a variety of both hand and machine operations before they are finished blades. The same goes for the handle pieces. If I had to put a number to it, I'd have to say that Chris' knives are well over 50% hand ground and finished depending if you look at it from a "material removed" or a "operations" stand point. If it's material removed, I'd say it's 50% machine, if you look at it from a time spent per operation, I'd say it's more like 80% hand made. When I worked there we had 19 employees and it took us a month to completely finish just 600-700 knives. I don't think it would be fair to Chris for me to list all of the operations that go into making one of his knives, but trust me, even the CNC part of it has to be setup and controlled by someone's hands and it only get the blade, maybe, halfway shaped. When I take time to think about all of the hand operations that go into making one of his knives, it amazes me that he can turn out as many knives a month as he does. Chris has some extremely talented folks (knife makers) that work(ed) in his shop, a few of them make their own knives on the side. Bryan Baker and Matt Otto come to mind.
 
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