Battle of the 3D Printed Knives – Round 2 – Entry #1

When the competition started I saw the other contestants were going all out with very complex designs and very functional knives. Mine was so simple and boring.

I then started looking on the internet to see what blade shapes there were out there, when I came across a “Dao Knife” a knife version of a Chinese fighting knife.

Scott Gregson

3D Printed Knife – Scott Gregson Entry #1

This is Scott’s 1st knife submission.

To begin I have always wanted a proper Cut Throat. I’d looked into buying a quality cut throat knife (a.k.a. a straight razor) and it’s very expensive. When I was given the opportunity to take part in this competition, I knew from the start, I was going to make a cut throat knife.

When round #2 of the competition started, I noticed that the other contestants were going all out with very complex designs and very functional knives. In contrast, my knife design was so simple and boring.

Slightly intimidated, I then started looking on the internet to see what blade shapes there were out there. When I came across a “Dao Knife”, a knife version of a Chinese fighting sword.

I liked the Dao knife shape as it resembles the cut throat a lot and I really wanted a cut throat knife. So I decided to make a hybrid of the two knives.

Whilst sketching out my blended design, something was bothering me about the shape — I really didn’t like how it was evolving.

It was too far away from my original Idea of a cut throat knife. So I started to adapt my sketches,

First, I made the scalloped edge much steeper. With the handle, I experimented with thinning out the handle. Finally, I modified the curve on the cutting edge, bringing the look of the knife more in line with a cut throat but still maintaining elements of a Dao.

Seeing the versatility of the other contestants’ knives, I thought to add in a bottle opener and a wire stripper to my knife design.

As this is the first real knife I have ever made, I ended up opting against these additions as they would weaken my blade. Instead of trying to be clever, I decided that if people like my knife, they will like it for what it is and not for the added extras.

At this point I sketched out the profile of my knife blade and laser cut it from a piece of 3mm Masonite to get a feel of the size and shape in reality.

As I am new to the team here at Akhani 3D, I was unfamiliar with the 3D modelling program used here, so I reverted to my draughting roots. This also helped me draw up and complete a new sketch that was to scale.

Slowly but surely I struggled my way through the drawing process on a 3D CAD program I didn’t know. I often had to stop and ask Jason for help. Eventually I got to the point where it looked like I had a knife.

At this point, we decided to 3D print a prototype of our knives using Nylon to see how they would work, how they would feel, and to test out the fit and function.

My knife components fit together really well. The shape and feel was absolutely awesome in my hand. It made me feel like I wanted a shave. I was really proud of my first attempt.

Considering my competitors, I came to the realisation that, although my knife was a really awesome shape, it was still very plain. So, with a lot of help from Jason, I started to look at how I could give my handle some definition. 

While discussing this with Dave, I mentioned that I wanted to etch a skull into my blade to keep with the cut throat “danger” sort of theme. Dave reminded me that with 3D printing we can make almost anything. Why didn’t I incorporate the skull into the pins. This will really show off our 3D printing capabilities here at Akhani 3D.

This led me to an epiphany. I was battling to place the scale mounting pins, as my handle is so thin. But with Dave’s advice, I realised I could simply design the mounting pins to protrude from the main body, instead of passing through the whole handle. This was a game changer and the pins can be whatever shape I wanted — in this case, a skull.

I have tried to make my knife as “dangerous looking” as possible, as I feel it best fits the theme I have chosen.

I realised I needed to put a “knob” on the blade for safe opening and closing. 

I remembered that back when I was studying our one lecturer always said, that if you ever create something that you are proud of, always put your name on it. So I added my draughting signature.

And so now we wait for the parts to be metal 3D printed and the final product to take shape. Watch this space …

3D Printed Prototype: SLS 3D printed PA-12 Nylon.

Post processing on a DyeMansion Powershot S using PolyShot Surfacing (mechanical) and dyed using DyeMansion DeepDye Coloring on a DyeMansion DM60.