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Home , Cheese knife, Cleaver, Global (cutlery), Kitchen knife, Knife making, Knife sharpening

Page 1 Index.

• Introduction 3 • Target Market 4 • Product Requirements 5 • Anatomy of a 6 • Project Brief and Rejected Concepts 7 • Brand Development 9 • Brand Details 10 • Materials 11 • Production Processes 12 • Knife Parts and Shape 15 • Sketching and PPP development 17 • IKB Project Evaluation 27 • Continuing Project from IKB to LARP Weapon 28 • New Brief and product specification 29 • Construction Praying Mantis LARP weapon 30 • Bibliography 35

Page 2 Introduction The Kiyoshi project started as a group university project called IKB to design a brand and range of products. The groups designed the brand. Then the next part of the project was a solo product design project for a product that fits with the brand. The product picked was a high grade steel or ceramic multi- use knife. This was developed with the honest intention to produce an item for a chef’s kitchen with Japanese craftsmanship. The form however developed into a shape that whilst met the brief of a high end , had two flaws. 1. The problem with a multi-use kitchen knife is cross contamination of . 2. The form was also suited to combat use. By accident had developed an extremely efficient hand to hand weapon system would work well with natural body flowing movements. The project evaluation stated that this therefore should not continue to a commercial kitchen knife that would be available to the public as too dangerous in the wrong hands, given the current level of youth crime. This is how the university project ended. However an alternative use was found for the research in the form of a prop weapon that could be added to the Merlin’s Armoury portfolio. An item that could be used in fancy dress, as a toy and to test out how the combat use could be done. This section is titled the Praying Mantis and covers the development of the foam latex ‘toy’ weapon.

Page 3 would be likely to be middle to a lot better then most they know. upper middle class, seeking to eat Target Market. This a super slick super knife can healthily. A, B, C1 demographic, fit within the product brief that At the high end of the market with a job that not only pays well fits under the those wanting for kitchen products there The but provides the time to well. Kiyoshi knife is an attempt to to emulate professionals. produce a high end product to Mid 20s possibly through to early 30s. Most likely single or in early appeal to professionals, those Thus in this case whilst the multi-- stage relationships, confident, looking to emulate them and use Kiyoshi knife carries out many successful, in a job he likes, those with money wanting the chef tasks, top chefs would prefer with an active sex and social latest cool kitchen gadget to use single use specialist . However life, possibly often entertaining and show to friends for bling look the knife gives the impression of colleagues, possible clients at at my cool value. professionalism in the amount . They would be aiming to of tasks it can carry out, with the Having had a look at top kitchen impress, both in terms of the food exceptional sharpness and high grade knife suppliers there appeared they have learned to produce and steel and sleek look. Plus the quality to be little that had not already also show off their tools. In this carry case it could turn up with and been provided for and provided case the target market is more its care kit including stone. for well. likely to be male as the showing There was the option to try and off of status symbol ‘toys’ is When not showing off produce a single use tool, or one more of a male trait going back abilities and cooking toys, that combines several uses in one to then they were a boy, where our potential client would be innovative and multiuse tool or they would impress friends with watching shows such as Top kit. Whilst attempts were made to items such as a light sabre, radio Gear or the Gadget Show, read speak to professionals. Feed back controlled toy, scary gadget, magazines like Stuff and FHM. was not coming, so precise needs cool computer game, the latest More refined than the likes of for professionals (such as single use trainers, a rare comic etc. This Loaded or Nuts but still featuring tools)could not be done hence the trait does not change as the male hot women. He may well have a error of developing a multiuse tool. gets older, just the toys change to sports car or get a car customised. items such as a car, motorcycle, The later was chosen as there This is someone who can afford big screen television, DIY tool, car appeared to be a gap in the to do adventure sports and the sound system, Ipad and so on. market for something new that car helps get to locations, such could have value in that it was This showing off will carry through as a good sport for hang gliding something unique and new. to what they try and cook such as or scuba diving. Enjoying active amazing cakes, which usually are holidays with a house full of This is therefore aimed more more time and effort. Such an gadgets as well as the kitchen, at those wanting to emulate item could be made to impress a with a book shelf of recipes, professionals rather than the girl, so they have a pleasant night maybe even competing in TV professionals theme selves. or a boss to get a raise. They don’t cookery competitions. The ‘wannabee chef emulator’ have to be a top professional, just Page 4 the back. Above which is the 18. Chemicals must not leach a hammer action to crush 30. It will need a highly polished Product attachment. from knife or hand made. garlics and tenderise meat, surface, not just for looks but care needs to be noted where cleaning and slip. 9. There will also be the option 19. The handle materials and the pointed end goes. Notably Requirements to attach another handle over bonding must be able 31. A varied to carry out towards the upper chest. the from blade. to handle heat, water, different tasks. The Kiyoshi Knife combines: Thus a element needs to be pressure from dishwashers 10. The attachment handle has to incorporated as a safety 32. A straight taper common in 1. The ability to intricately carve even though with regards have a strong reliable grip on . high quality for displays on a scalpel to professional quality the blades and grip the hand level with an attachment knives dishwashers are not 24. Soft meats like fish can stick 33. To be forged. as well to avoid it becoming a interface. recommended. to the blade so adding fluting projectile. 34. Decorative handle possibly or indents in the blade can 2. The ability to fruit with a 20. Care instructions need to be with abalone inserts. 11. The attachment handle needs to provide air pockets which hook blade at the front. included including washing protect the handler from the very act like a blood grove in a 3. The ability to slice open instructions and how they sharp blade and not wear out. sword so the knife just slides Distribution delicate fruit and should never be placed in through the material. like tomatoes with the 12. The attachment handle a wash where a hand A production run of 400,000 serrated front barb blade. needs to protect the knife entering the bowl could 25. Adding some synthetic was stated. Much of the with out blunting it. connect with the blade. rubber to the handle would process as can be seen in the 4. Razor sharp chopping and slicing help comfort and grip. production videos further on knife that will be fluted (air 13. With the handle in place the 21. Top quality metals are to can be automated. Sharpening pockets in blade) to enable soft knife can be used in a similar be used. These include 26. The surface needs to be and finishing is still a skilled meats such fish to be sliced and configuration to a to crack around as seem less as possible job. This would be a premium filleted effortlessly just sliding off bones and open coconut. a ceramic or sintered avoiding nooks and crannies product, costing over £100. With powdered metallurgy core. where food items can rot and the blade. 14. The handle/hilt needs to multiple processes. It would be The hardest infect food. 5. A flat middle blade section be comfortable for a wide aimed at grown ups. The outlets produced this was is Cowery for fine and rapid chopping percentile. 27. The packaging must be clear could be department stores, the X with a Rockwell Hardness of herbs in line with the table this is a professional knife internet, specialist chef stores, 15. The handle needs to be Rating of 67. and not for children. Given gadget shops, strictly an over 21s underneath. comfortable in various 22. As super hard steels can be its capabilities it should be product. 6. The back of the blade will configurations including the more prone to chipping, kept from teenagers as well. have small curve to prevent scalpel configuration there Marketing could be in gadget the rear end intended to it getting caught on the the knife is held upside down 28. This needs to be sold in a and chef trade press, high end handle bone and coconuts, chopping boards. and backwards. manner which stops young cooking websites and magazines. will need to feature tougher people getting hold of it. The This is a product built to last with 7. Behind that is a concave gripper 16. The handle needs to stay as opposed to the hardest price will help here. a price to match. with dull spikes to hold items permanently attached to metals, with the card core whilst chopping with these razor the knife. further up in the blade. The 29. Laminated steel and similar also applies to the hammer/ processes can form part of sharp knives. 17. The handle needs to blend crusher section. the marketing as well as 8. A / garlic seemlessly with the knife producing a knife quality crusher hammer pommel at 23. As the knife can be used in body with a full tang. product Page 5 Anatomy of a Knife

Hilt / Handle Material The hilt/handle is usually added with 2 or 3 flat rivets and with quality knives the transition of blade to handle is seem less to avoid tripping bacteria and allowing water and friction to weaken the bond between knife and handle. In some cases like knives there is no extra handle or hilt. Just one metal product with a hollowed out handle that can be filled with sand and shaped to give grip with dents and ridges. Materials include bone, shell, horn, , synthetic rubber, composite fibre or resin composites such as Packwood, metal such as aluminium and . Plastic tends to wear out and apart, synthetic rubber needs to be sealed in but can provide a softer more comfortable grip. In general high end products feature hard handles. Wood tends to feel warm, metal cold. Wood can warm and crack but not when sealed with resin to form a composite material which seems best. Ideally inlaid with decorative materials such as small amounts of abalone too small to break.

Page 6 have small dull blades that could Brief. have safety extractions or blunted features. The problem with small The brief was to be carried out in dull blades is they are not effective two halves. as a cooking utensil which may Part one was as a group, come put off the boys if they cannot to up with a concept for a brand of the job properly. At present there innovative kitchen utensils then is a major problem with knife separate to design one of these crime especially amongst young each that fits the brand brief. teenagers with figures Note sketches have been handed http://www.insight-security. in with graphics. com/facts-knife-crime-stats.htm “Paragraph 9 Initial Concepts The new figures indicate that In the group I was the first to in the year 2007-8 there were come up with two concepts over some 277 deaths from stabbings the Christmas holidays. in England & Wales alone (the highest recorded figure for Brand Concept One. 30 years). This represents an Boys Bond with Dad average death toll as a direct result of stabbings of over 5 for Was for a family bonding product. every week of the year! A collection of kitchen items with horror, pirate or science fiction Paragraph 19 themes that could be used to prepare and serve food. The (Some estimate that as many theme design to be used by fathers as 4 out of every 5 incidents go to entice young sons into cooking, unreported), and are therefore which may be perceived by many not included in the reported as a ‘sissy’ or ‘girly’ pursuit despite crime statistics.” the number of male including celebrity chefs. This would include This put the pirate knife idea in items to produce chocolate skulls a bad light as it could encourage and coins, Colours could include more kids to see knives as a metallic purples, blues, and blacks, weapon and toy. greens, with designs like skull and cross bones or snakes. Items meant for children to use could Page 7 Brand Concept Two children.) The essence here would Naughty Couple be around ‘love making’ as opposed to a ‘cold fuck’. Not Bonding Flirt Food meant to be perceive as a This was for a sex and fun themed perverted, sleazy, scary item brand. The kind that would be sold more hot passion, romance, in shops such as Ann Summers, playfully naughty and in novelty party stores aimed at mischievous, cuddles, getting young couples, 18th and 21st snugly, playful and jokey. Items birthdays of females, hen nights, being make from injection romantic and valentine gifts and moulded ideally so called Ann Summers sales with bacteria/virus resistant parties for ladies etc. Intended as elements. Alginate moulding a fun way of involving cooking in kits would also be supplied and a couples love play, and flirt antics good repeat follow on purchase that reinforce their relationship, via a company website encourage more affection and increasing follow on profits. love , making it all fun This had a lot of potential to combined with cooking... Though go with in terms of breath of in this case the cooking probably items to produce and ease does not get finished as the of manufacture, plus large dining table may end up used for consumer base, but the more ‘physical activities’ and the problem with groups is you food end up all over both parties are stuck with those you are involved. placed with who don’t think This would be targeted to be like you. The rest of the groups female friendly, warm pink were too scared, prudish, shy, and other fun friendly ‘cuddly’ embarrassed and wimpish to go colours. There would be ways of with this concept. On my own I moulding body parts, more the would have gone with this as intimate ones, which then could stirring up controversy is a good be used to mould food items like thing, challenging hegemony, cakes and chocolates or jellies. and quite frankly it would have been fun, producing a fun In many ways like a child’s play brand that helps couples have cooking set only a play set for fun and get closer together and grown ups (which may end up a all the appropriate, key element in producing more conservative types. Page 8 Selected Brand Development The group started to think in terms of high quality items using the best Japanese bladed . I wanted to push to more of the modern style based around quality and colourful Japanese hot rod custom street cars, motorbikes, two tone paint, action heroes characters which frequent television thriller series at present, giving female strong, exciting role models. Bright shiny metallic colours. This can be associated with hi technology gadgets, stylized curved bladed customised exotic weapons, ninjas, highly trained assassins, spies, high athletic ability as seen in extreme sports such as parkour, snowboarding. Everything exciting, wild, energetic. Other members in the groups wanted to steer more towards minimalist, top professional level products aimed at top chefs and those wanting to emulate them. A young, energized, quality, technology, gadget, outgoing brand. Initially to be called Tigerblade to convey a cool, slick, fast, powerful, modern essence, with high pride of craftsmanship quality. However the group wished to move to a less blade specific brand name, far blander, aimed more to traditional chefs, with a minimalist refined brand they named Kiyoshi, Japanese for Fresh. I was against the professional minimised shift seeing problems with designing for professional & hating the minimalist feel finding it dull. But out voted. However got the group to compromise combining elements of both. Brand Elements Having developed a brand that projects top quality, aiming at both professionals and that wanting top quality equipment, which is stylish, modern technology, combined with the ancient Japanese pride in the outstanding quality of craftsmanship several issues need to be considered. Japan has a reputation for top metallurgy, in their ultra sharp and tough blades. The elements must blend effortlessly, with sleek curves and perfect ergonomics feeling part of the • The Production Process user themselves. • The shape and configuration These items are to be sold in top professional suppliers, Looking at the concept, the logical thing to do with developing JAPANESE expensive department stores, a product aimed at professionals would be to go and ask some. sold by traders who know their Previous experience working with film companies catering to high KNIFE COMPANY products. Company reputation end clients pointed out that the Soho area in London would be a good will be a key here, word of bet featuring several top . Despite visiting many in a day mouth and reputation over including : television advertising. By their • The IVY: http://www.the-ivy.co.uk/menus/roasts-grills-entrees/ nature these are most certainly not to be sold to teenagers or • Floridita : http://www.floridita.co.uk/london/ children. The packaging will be • Souk: http://www.soukrestaurant.co.uk important, most likely supplied by an exquisitely crafted box As well as exotic cake designers Patisserie Valerie who produce some very professionals. that the user can store them exotic looking items that look as good as they taste requiring some skill to in or magnetic wall hanging produce. I could not find anyone willing to take the time to talk to me or Wüsthof, Henckles, Matfer and Global. More research found ceramic with their own knife care kit email suggestions. specialist , the Japanese Knife company & top knife craftsman Ichiro Hattori. including sharpening stones. http://www.patisserie-valerie.co.uk/special-occasion-cakes.aspx Their websites can be found here: To develop a high quality knife The only action that helped was to join Jamie Oliver’s company forum. product three areas need to be http://www.wusthof.com/desktopdefault.aspx/tabid-21/52_view-159/ looked at: http://www.jamieoliver.com/forum/viewtopic. categories-159 php?pid=622761#p622761 • The Material http://www.j-a-henckels.com/en-US/Product-Range--sortiment/ Posters there suggested the following companies as selling towards --knives/Chapter--kapitel/Recognizing-a-good-knife--2676.html Page 10 http://www.matferbourgeatusa. Looking at the traditional However a dark volcanic like is very hard. It’s the second like a pro. com/ weapons on tribes such as the material known as is far hardest material, right after http://www.globalknives. New Zealand Maori, wood more effective which unlike other diamonds. After it’s sharpened, * - No metal means no uk.com/knife-features weapons and stone weapons materials it has no crystalline it can keep it’s razor sharp rust.” can be very effective, and heat structure. However it proved so edge and will not wear out. If http://www. Cite: japaneseknifecompany.com/ processes can provide hardening effective it is still in use today you ever do need to sharpen KNIVES/tabid/54/Default.aspx processes. Bone is easy to in the highest quality surgical it, most of the manufacturers (http://www.myceramicknives. work with producing intricate blades as: will sharpen it for free. com/ceramic-vs-metal/) http://www.japanesechefsknife. shapes, along with stone like Manufacturers of metals knives com/HATTORI.html “Obsidian has been used for (Cite: jade. Teeth (such as shark teeth) will never offer you that service blades in surgery, as well-crafted come readily sharpened and since they need to be sharpened http://www.theknifeshop. obsidian blades have a cutting hard. Wood is often still used in so often. co.uk/Pages/content/306.html ) Materials edge many times sharper than chopping boards, (However it is high-quality steel surgical However just using the hardest The material used is a key factor. getting superseded by synthetics * ODORS - Ceramic material , the cutting edge of material going will not work It has to handle many issues. such as nylon which can resist is not very porous at all. the blade being only about 3 perfectly as the harder it is, the Processes in blade production bacteriological ingress better). This keeps the blade from nanometres thick” more brittle. Ceramic blades are only one part of what makes Spoons and handles, plus items transferring odours from one are useful with fruit and fish, an item top quality. All these like sushi mats and steamers. Cite: http://en.wikipedia.org/ food item to another. You but are more likely to chip or processes would not be much use wiki/Obsidian can cut something spicy, give However whilst wood may suit shatter when presented with with soft copper. In ceramics the hardness of a it a quick rinse and then cut harder materials like bone, and various kitchen products or something else. The spiciness The blades have to cut, and stay material is measured in Mohs. break easy if dropped or bumped parts such as chopping boards, won’t transfer to the next food sharp, for a professional this Most modern ceramic knives against other hard tools. This is a spoons, utensil holders, sushi item. means exceptional sharpness. mats, handles, it is of little use as are mostly made from Zirconium particular problem when dealing Oxide second only to diamond with food. Small chips going The blades can vary between a blade material when compared * SANITARY - Ceramic blades rated. unnoticed could cause horrific scalpel level for elaborate fruit to others. are very dense, with very little damage if swallowed. carvings and gently cutting “Diamond 10 mohs, Zirconium pores. Just like your face, the tomatoes. To cutting bones At the upper ends of the market the two most common materials Oxide 8.2 mohs,” fewer pores there are, the less and butchering pig carcasses or dirt and grime can get into the Metallurgy. are ceramics and high By comparison the hardest opening coconuts. pores. A quick rinse in warm stainless steel. carbon steels rate 6.5 on this Chefs blades need to deal various water will get your ceramic whilst most stainless steels are considerations. Organics knife a lot cleaner than a Ceramics closer to 5.5. They have to be able to combine The oldest materials for knives thorough scrubbing on a metal After organic materials came Cite (http://www.knife-making- knife. the need to process the metal are bone, tooth and wood. Wood supplies.net/rockwell-hardness- into the required shape down being the most readily available ceramics. Chipped flint is the scale.html) * WEIGHT - Ceramic material to microscopic tolerances. To be material is the most readily most commonly known ancient is very light weight. The lighter heated, hammered and crushed, available and easiest to sharpen. tool material. But is it not the This gives many advantages over the weight, the less strain heated and cooled rapidly, to Even apes, birds and otters have only one. Soft stone like jade has steel. on your arms and shoulders. harden, annealed to remove used wood and rock tools. a long history of use in weapons, and hunting items. “ * SHARPNESS - The materials You can rip through all you’re brittleness, heat softened to that make up a ceramic blade Page 11 form fine grain structures, to be stainless steels that can contain properties needed. Laminated Ceramic/ Zirconium duty out of unrolled sheets of cold polished, which then fine ground the following steel is generally considered the rolled steel, edges sharpened by to a razor edge. Once constructed best metal material, combining Oxide Blade grinding the edge then attaching “CARBON - a mineral that is it must keep its shape and welded and forged layers of soft to handles. Thin flat blades with responsible for transforming Production sharpness, resist corrosion, low carbon and hard high carbon just a ground edge are a sign of into steel. Carbon adds staining, must not contaminate steel. Developed from weaponry this process. Often just 55 on hardness to a steel. The higher Ceramic blades are formed by food, handling repeated washing this dates back to its use in Rockwell hardness scale the carbon content, the better pressing purified Zirconium Oxide in hot water and detergents. during the crusades, referred the steel is able to hold an edge. powder into blunt blank shape This may be called a ‘stock to as Damascus steel and more Whilst all knives are meant to using presses that crush compact removal method’ as it involves commonly talked about in the for fill this criteria, professional - enhances the material with over 300 tonnes cutting or grinding away metal construction of the Japanese quality knives are judged on how toughness and harden ability. of pressure, the brittle knifes till you have something that Samurai Katana. The softer steels sharp they can be made and how are then sintered by heating resembles a knife blade. With providing toughness and some well they maintain that sharpness - boosts steel’s the compressed material to just or without hardening and flexibility preventing the harder and for fill the above criteria and resistance to corrosion and under its melting point which . blade edge steels from fracturing for how long. Material choice is staining. fuses the particles together to or chipping, whilst the harder (Cite http://www.knife-making- therefore an important issue. particles to form a super hard Usually 16-18% steels hold the material solid material that can then only be supplies.net) The scale by which blade and provide the cutting edge. ground by diamond dust coated This is keeping it simple, quick hardness can be assessed is - yields a fine grain Damascus steel may be folded grinder by highly trained and cheap production. A basic called the Rockwell C scale. Based in the steel during the heat 100s of times. craftsmen or women. As can be stamped cook’s knife in a store on how much of a dent will be treatment process. But modern technology has taken seen in the following video. such as Wilkinson’s may cost a left in the metal when a diamond this even further with particle few pounds. The process rapidly tipped probe is pressed into the MOLYBDENUM - used to Cite metallurgy with production produces lightweight, flat blades material. increase toughness in tool steels http://www.youtube.com/ that are then attached to handles. such as D2 and A2. processes more like that seen watch?v=JFnT5INymiY Whilst titanium may be used to in ceramic blade manufacture This produces soft, light, badly produce blades they tend to be TUNGSTEN - aids in producing producing hardness ratings as balanced, knives, poorly attached brittle so steel is the main metal a fine yet dense steel grain high as 67 Metal Blade to handles. Such knives are harder used. structure. “ to handle due to their lack of Steel is an alloy of iron, carbon Production weigh and balance. Often due Cite: to a lack of hardening processes and other metals. The higher All of these companies were clear and low density steel lacking heat the carbon element the harder (“http://www.knife-making- on one thing. That quality knives supplies.net/knife-blade-blanks. compression they do not hold their the steel, however too much and were drop forged as opposed to html”) edge long. Also blades often lack a you just have a brittle material stamping. full tang. The tang being length of of little use. High is The Global brand boast that their the blade metal that extends into also prone to corrosion. Not a steel is so stain resistant due to Stamped Blades the hilt/handle. This leads to poor good thing in food preparation. the high 18 % chromium content. Chromium counters this. There In its most simplest definition quality connections with hilt and are many grades but the most Alloy composites are not the only stamped blades are die cut (Think blade coming loose, losing control suitable are high carbon, 440C way to combine the required cookie cutter only far more heavy of the blade at joints. Page 12 Some of these features can be VideoPlayer.aspx?movie=http:// to prevent fractures. Grinding described here: www.wusthof.com/ helps shape the blade taper and Portaldata/1/Resources/ http://www.youtube.com/ provides the edge, polishing, medienbibliothek/videos/ not only makes the blade look watch?v=XGmERKgXnuQ Wusthof-Production-Video. flv&image=http://www. pretty, it prevents staining and Forged Knives wusthof.com/Portaldata/1/ corrosion, sealing the metal and Resources/medienbibliothek/ keeping out bacteria. Finishing Forging is one of the earliest videos/images/hdl_Wusthof.jpg with fine hand grinding with wet production processes. In simple stones to finalise the razor edge. In modern processing this starts terms it is taking a big blank lump with a rough shaped blank lump of As mentioned unlike many cheap of metal, heating it till malleable high carbon stainless steel, which stamped blades, forged knives then hammering it into the is then drop forged in a modern are effectively one piece or metal right shape. This loosing little mechanised version of the old that covers the entire length of of the metal, thus less wastage craft of the blacksmith. Here the the knife thus a full tang. The casing which will be riveted on. knives-671222.html making it a far more material I sign of quality is the seamless metal is heated to over 1,100 handles are there for comfort Modern stamping may be closing efficient process. The compacting smooth construction here which degrees Celsius, then hammered and handling, around the hilt of this gap with better quality producing a far harder and makes the while knife feel one into shape in a die. In earlier the blade. Not to structure it. steels, but forged knives are still stronger metal item. Ground smooth, the hand times this would have been done With Global Knives they have no favoured. Forged knives usually involve by hand with a hammer on an extra handle; the knives are one sharpened with final grinding. far more follow up processes. anvil, now the process features piece of metal with a shaped hilt Whilst different manufactures Including tempering, annealing, industrial hammer with far more that unlike other brands is hollow may differ from this process, Laminated grinding, cleaning, polishing, power with possibly one very to be filled with sand to weigh most top quality brands follow inspections along the way to tight hard strike. them. Others have the outer hilt these processes to produce a tool Forged Steel tolerances. This means a longer that combines extreme hardness, Heating the metal to over 1000 The ultimate but most labour production time, more expensive. tough ductility, and a polished degrees Celsius compresses the intensive and slowest process is Equipment, more skilled workers, seem less surface as well as a metal without work hardening, the forging of forge-welded or heavier duty equipment as well comfortable weight. A distinct deforming the continuous pattern wielding (Where heat and as the safety issues surrounding difference between stamped grain in the metal block whilst pressure wields layers of different hot metal and the energy needed and forged blades is the weight. keeping it continuous. This is steels together, commonly referred to crush the metal. Thus far more Forged blades being far denser then hardened and tempered by to as folded steel) laminated steel expensive. Forged knives can cost and thicker hold more weight. heating it up slowly in a furnace blades. The metals used in these ten to twenty times the cost, This feels more stable and to over 1000 degrees then rapidly processes are considered almost often well into three figures. balanced giving far more control cooled so the outside becomes top of the range. They have a clear to the professional. The Wüsthof website features a very hard. Annealing comes next mottled pattern where the grain video showing how this process which removes the brittleness, Cite: can be seen after acid etching. This works in a modern forging so the inside still has flex. Thus is predominately a hand crafted factory: producing a very hard sharp http://www.articlesbase.com/ home-improvement-articles/ process and batches can take many http://www.wusthof.com/ hardened blade that keeps its knife-sharpening-experts- days to produce but the blade edges PortalData/1/Modules/ edge, but with enough ductility stamped-knives-vs-forged- can have hardness ratings of over 60. Page 13 They can have over 100 layers of This contains: These include: different steel types where each • Iron 95.22% to 98.12% • SRS-15 (Rockwell 64-65) fold multiplies the layers to the power of 2. Generally mixing • Carbon 0.10% to 3.00% • Carbon 1.5% stainless and high carbon steels • Copper 1.54% • Chromium 13 % This is often misdescribed as • Manganese 0.11% • Molybdenum 2.75% Damascus steel which was Rh rated 55, the formula lost in the 1700s). • Tungsten 0.05% • Tungsten 1.55 % Now it is used to describe any • Molybdenum 0.04% • Vanadium 1.5% pattern wielded laminated steel with modern versions reaching RH • Titanium 0.02% http://zknives.com/knives/ 60 mixing high carbon and stainless steels/srs-15.shtml • Silicon varying amount steels. ZDP-189 or MC66 (Micro Carbide • Miscellaneous compounds Cite: with 66 Rockwell rating) Trace amount http://www.cutleryandmore. • Carbon 3% com/japanese-kitchen-knives Cite: • Chromium 20 % Often in knives it is not just a http://www.cutleryandmore. com/tamahagane-kyoto/ • Molybdenum 1.3 % random folded mix but softer damascus-- tougher steels surrounding knife-p117866 • Tungsten 1.5 % super hard steel such as cobalt http://en.wikipedia.org/wiki/ • Vanadium 0.1 % containing: Japanese_swordsmithing http://zknives.com/knives/ VG-10 Rated 61 on the Rockwell steels/zdp-189.shtml scale which contains: Laminated Forged Used in Henckles Twin Cermax • Carbon:1.0% Steel with Powdered range: • Chromium:15.0% Steel Cores http://www.cutleryandmore. com/henckels-twin-cermax/ • Molybdenum:1.0% Modern technology has taken chefs-knife-p19688 this even further with forge • Vanadium:0.2% • 1% Molybdenum wielded laminated blade particle On current top • Cobalt:1.5% metallurgy containing steel Cowry X rated up to 67 without • 0.3% Vanadium cores produced by techniques Cite: brittleness on the Rockwell scale, Cite similar to ceramic blades using and is a powered alloy to be http://en.wikipedia.org/wiki/ compacted powered steel alloys http://www.japanesechefsknife.com/KDSeries.html#WIDTH:%20 VG-10 sintered in a similar manner to that are then sintered. ceramic blades which contains: 368px;%20HEIGHT:%20258px Tamahagane steel (Rockwell http://www.youtube.com/ • Carbon (3%) Various materials are used for knife handles. The best systems involve a 61 and the base to the famous watch?v=1Mjsi2F2MrY full tang where the knife is effectively one object with the handled simply hand made Japanese Katana) • Chromium (20%) there for a comfortable grip. The norm on forged blades. Handles are Page 14 Now you have the effect of production process and materials. The next thing to look at in the development of a top knife is the shape and configuration and it is here that the variety of top grade knifes totally expands with different knives for all manner of cooking related requirements, log, short, pointed, blunt, dented, hollow, big , small there are all kinds. Serrated blades work well when you have a tough outside but soft inside without fibres such as bread, tomatoes, and kiwi fruit. These lightly catch the thin skins slicing them open without crushing the contents inside. As the forces are focussed they have more penetrative power then a sharp blade spread over an area. Once in the hooks can then attack the edge rather than the thin surface with offers less resistance. Such knives only work well in a drawing motion, pressed down they have little cutting ability. They will tend to get caught on and tear where there are fibres present such is in meat. Smooth blades can be pressed down or sliced, in many cases having a curve to the blade, runs more cutting surface across it giving clean cuts across meats. Super sharp hardened blades such as ceramics and those Page 15 • Super sharp anti stick knifes for fish and soft fruit. containing particle metallurgy • Peeling knives. hardened cores are excellent on soft meats like raw fish and • Boning knives vegetables. These professional which need to be santoku knives have indents/ able to handle fluting to make air pockets to • Bone & cartilage. prevent sticking, in a similar manner to cheese knives like • Heavy chopping below. But when cutting bones . a little less hardness and more • , toughness to avoid chipping may help. Then a heavier large thick • Serrated bread blade like a cleaver is required. and soft fruit Hardness is important, but knives. tempered with toughness to • Tweezers. prevent shattering. • , Chefs will need a range of knives that can cover all the things they • may need to deal with: • Probes General Chef’s knife for many • knives general tasks. • Flexible knives • And other specialist tools

Page 16 make paper thin sheet strips Product of chocolate for decorative cakes such as that produced Development by Patisserie Valerie. Then annoyances about difficulties and PPPS in slicing into dense vegetables such as swedes Having looked up the elements and sweet potatoes gave rise that go into a high quality to the notion of solving this kitchen tool, something suitable problem. Use of something for professionals and also what like a cleaver did not look those wanting top quality kitchen practical as inaccurate and products may purchase as kitchen hazardous, regular knives bling to show off, and to try and were getting stuck. It was produce quality cuisine, the next when a herb step was to put this knowledge called a was together and think up something observed and Shuang Gou new. swords or more so the As mentioned attempts were guards over the hilts. That made to try and find out what a concept for a knife that professionals used, purchased and could utilise the users body what would be a popular need weight to push down with or wish, something that could a crush cut through dense solve a problem they had. But vegetables was thought nobody responded to attempts up that soon developed making design techniques such into a concept for a novel as accurate persona profiling , multi- use knife that could scenarios and story boards pretty incorporate several different impossible. Lacking the feedback professional kitchen blade from professionals other than tools. With hindsight this being pointed towards some high now appears to have been quality suppliers it was necessary the wrong decision which to go off and try and think of will be explained later. something not currently available. Sketch work and was Some ideas such as a means of started and a first chopping onions without tears, prototype. Sketches for this rapid chopping of vegetables with development are now with a comb like device and a chocolate James Lamb. tool that could be useful to Page 17 1. The first yellow foam model ability, for slicing. It can roll was a wide crescent wide cut herbs like a mezzaluna, The first yellow foam model be handled in various ways. was a wide crescent wide The possibility of detaching fluted blade with a handle the blades is considered. above to apply a crush force However the danger of the or thin slice. This appeared knife coming apart, the workable with simulated inherent weak point in the indents on the blade. Playing systems and the scope for with the first model gave an hard to clean areas causing indication that there was infection led to the idea a good amount of scope being rejected. The point, for a versatile tool. It felt curviness of the blade and reasonably comfortable. This position of the handle show appeared to be too large. it could penetrate deep into It was clear the knife could something such as a turkey fluted blade with a handle or be used to take apart a above to apply a crush force butchered carcass So you or thin slice. This appeared have a flat slicing, workable with simulated cutting, crushing, stabbing, indents on the blade. Playing herb chopping knife that with the first model gave an can be used in new different indication that there was ways to a normal knife. a good amount of scope for a versatile tool. It felt 2. The second prototype was reasonably comfortable. This too large, the shape was appeared to be too large. It refined a bit and more of a 3D was clear the knife could be feel added, this proved more used in various ways to slice. comfortable. With a better A chef knife element was grip it was more controllable added which then appeared and comfortable, the handle to vastly increase the tools gap is still way to big. scope. Flutes or indents on the blade if this was real combined with top grade forged laminated steel would enable the user to fillet fish, slice meat, the curved blade increases the cutting Page 18 Page 19 3. Here you can see the development of the handle with the front down slop for the thumb and curvature to fit the palm of the hand. A further of the hand gap was added later. Above and to the left you can see the fluting as well as the danger of the tip coming back towards the user when using the crusher on the back. 4. Noticed that the back end enabled a hammering motion that could crush garlic. However it soon got noticed that this motion sends the knife point strait towards the upper chest and head which looks very dangerous especially when the processing and materials would be aimed at producing the sharpest blade possible.

5. Indenting the bottom for the fingers increases comfort but different hand size percentile needs to be taken into account. So now you have a penetrating knife that can slice, cut, cop in various ways. That has a downward crush chopping capability. The knife comfortably handles in a flat filleting action, Can role on its underside curve, lightly chop or heavily crush cut. Page 20 6. Clay handles or hilts were experimented with. First a lump was crushed in the hand and then all the gaps filed to make the clay fit the hand. With no gaps. This produced a right hand sided only mould of a handle which was then dried in the . The result not only fits the hand it traps it. This would be very restricting as allows not hand movement. But is very hand supportive, It shows where the finger dents could be and that the handle should have a front hat is taped down to be comfortable for the thumb. This was not comfortable and was very restrictive so a subtler design was needed.

7. A second clay moulding was produced. This time

Page 21 the hand was moved around into all of the various positions. Holding the knife forwards, backwards, and the upside down backwards position to operate the scalpel blade attachment. This was repeatedly reworked till there was a smooth handle that fitted the hand in each position, with no flaps and in either hand. This was much more comfortable and versatile Page 22 8. This was carved into the next yellow foam ppp, the top handle was curved and dents were produced on the handles. 9. The handle was lowered. And indented for comfort both ends. And to accommodate the thumb and forefingers when upside down in scalpel mode.

Page 23 10. The hammer side had groves cut to add flattened spikes to produce a surface like a meat tenderizer. 11. The crescent under this has blunt spiked intended to act as a gripper which could be a safety advantage to keep fingers out of the way of the super sharp blade. 12. An attachment extension for a scalpel blade was added to an alcove at the back. The alcove needed so the attachment did not get damaged when the hammer motion was applied. Embedding real scalpel in this position proved the handle arrangement to do this would work out fine.

Page 24 13. To deal with the back stabbing when using the rear crusher, a barbed wider end is added to the tip. Serrations on this allow for soft fruit and bread roll cutting. 14. The rear of this section forced a curved hook/clawed blade to a point. This can be used to peel or score items, both very useful but its primary purpose is for safety so a flat end in line with the body, hits it if the crushing motion is done to hard sending the knife point towards the body and face. This way is there is a strike it is a flat edge hitting which would be unlikely to penetrate the chef’s clothes more than a set or serration prickles. 15. Two holes were added and more clay was used in combination with foam board to produce a handle that could encase the extended blade. To be attached with bolts. This could be used as an extra safety guard when using the knife in hammer / crusher mode. In addition this could turn the knife into a sort of cleaver. This could be used to open coconuts or cut bone. This would need the back end of the knife to be more tough than hard to avoid chipping or shattering. What this means is that the lamination should have the hardest phase of the forged knife should be in the front knife section. The rear section outer tougher steel could over lap so was the only phase at the back bottom of the blade where the hardened phase moves up a bit.

Page 25 16. Experiments were also carried out at this stage to assess the weight. Water displacement was used by placing a bucket, in a dry bowl, with water up to the very edge of the bucket. Place the knife in your fingers and hold underwater till the water stops flowing out. Then empty the displaced water in a measuring jug and assess the volume. Repeat the and record the results for different attempts to work out an average. 350 cm3 for the whole item and 250 cm3 for the handle and rear side. Then using the chart here with stainless steel being around 7480 to 8000 KG/m3 the mass was estimated between 2.6 and 2.8 kg indicating it needs thinning out, with 71% of the weight below the handle.

http://www.simetric.co.uk/si_metals.htm

Page 26 An alternative however could be to sell the design to film companies producing action movies IKB Project Evaluation where it would do well as a superhero or villains weapon pair allowing for breathtaking arm whirling choreography which looks good on camera. (Whereas in reality short hidden moves On the outset the concept seemed a good idea. A knife with a multitude of uses from the lightest work best but not so exciting on camera). Then soft and safe version could be mass produced as fine artistic fruit carving, to cracking coconuts and taking apart a defrosted gutted pork carcass, a merchandise toy. With weak soft metal version sold as movie replicas. constructed from high quality hardened and folded high cobalt steel, ultra strong and sharp, that could chop fast or allow the user to use their body to apply extra power. It sounds to the Unfortunately this is far removed from the original IKB brief. layperson to be a top quality professional product, one that would come in a beautifully crafted case, to be sold to top chefs, with descriptions of the craft work going into the construction of the knife utilising the latest technology and metallurgy that Japan was famous for in the construction of its samurai swords and other martial arts weapons. Ergonomics was incorporated in this to allow various ways to hold the knife for different tasks with weight to the rear. However whilst contact with real top chefs could not be done as they had no wish to help, further research has found that professionals prefer to have a collection of specialised single use tools. They can afford to own such a large collection; each item is idea for its purpose, not having to compromise in its configuration to be able to perform other tasks. In addition this prevents cross contamination from foodstuffs such as raw meat to vegetables. This however is not the primary issue with the product. The main issue is due to its size, shape, balance, sharpness it makes a very efficient weapon. Youth crime involving knives is very high at present. Most use regular kitchen knives used crudely either in a rush and multi- stab or pulled out in a fight, stabbing unseen, the victim not knowing what has happened immediately. This item when used as a pair with the knife held backwards so the blades run back along the forearms protects the user blocking strikes easily, then these open like some sort of praying mantis razor sharp talon blades with can be used very fast in a whirling motion, the lightness, balance and ergonomic handle providing precise use, the size and sharpness inflicting massive damage both from the blades and point, pulling out with the hook. Combine this with martial arts training you have what appears to be from a laypersons point of view a very efficient hand to hand weapon combination. Far more so than a standard cooks or chef’s knife. Whilst it may be possible to keep the item from teenagers and children’s hands by only selling through professional outlets at a premium price. Chefs probably would not favour it due to its multi- role use and different handling with the handle on top as opposed to the rear. This means a company selling this would be more likely to find other outlets putting the item in the hands of those it would seek to avoid. Another problem would be counter fitters. Others can copy the blade. Whilst the metal quality would not be so good avoiding the expensive high cobalt folded and forged steel. It is likely to be far more openly sold, possibly on the internet by far less scrupulous traders only interested in profit. Then right into the hands of those it was never intended for.

Page 27 Praying Mantis Knives

Continuing Project from IKB Kitchen Knife to LARP Weapon Having established that the multiuse kitchen knife concept had to be aborted after the assignment hand in, the research and development was redirected to a different outlet. As the system was geared more as a weapon applied the saying if you cannot beat it, join it. If it works well as a weapon system then develop it accordingly. • The blade was enlarged and the gripper on the back end replaced with a stabbing point and hook. • This was then remoulded for use as a toy LARP weapon that crossed the and short sword categories forming one of its own as the use was different to both categories. • The fighting technique ideal for these is for them to be used as a pair pointed backwards as slashing, hooking opponent’s weapons and body parts very effectively, both as a slashing and stabbing weapon as well as good for parrying. • The can be seen with a similar system in the film ‘Chronicles of Riddick’ at around 50 seconds in. http://www.youtube.com/ watch?v=36eHKHa9MuE • It would be ideal for use in enclosed spaces.

Page 28 Praying Mantis Knives

New Brief To develop and alter the design for suitability as a fantasy game toy weapon that gives the client an edge in competition mock battles but without inflicting any real harm.

Shredder Knives Product Specification. • Product needs to be able to do hooking, slashing and stabbing motions. • To ergonomically allow flowing movement around the body. • To protect the users hand and be useful to parry opponent strikes. • To minimise the chance of injury to opponents. • To hold the unit form. • To survive rough handling. • To minimise the chances of entering eye sockets.

Page 29 Praying Mantis Knives

Construction • As a toy or LARP (Live Action Role Playing) weapon the form needs to be 2 to 3 cm thick whilst a real blade would be a few millimetres thick. Other than that the shape would be similar to the prototypes. • The first task after committing to the form was to cut a card template to enable uniform blank foam cut outs.

Page 30 Praying Mantis Knives

• The next task was to build the skeletal structure out of fibre glass rods. Thin rods glued in drilled holes on the thicker tubes. Paper markers were wrapped around the tubes to help drilling. • These were thickened to level them with the foam sheets taking plastic from plastic spoons and glue gun glue. • The rods are squared off and roughened to help gluing into

Page 31 Praying Mantis Knives

the centre foam sheets. • Slots were carved into the foam for this structure that would combine the handle or hilt with the blade section. • After contact gluing with Dunlop Thixofix glue, this is reinforced with glue gun glue to fill the gaps cased by combining circular profile rods and square slots which also levels it off. • The next task was to reinforce the tips. Plastic plates were cut from margarine tubs. These were roughed up then glued into please over the tips of the rods. This was further reinforced with two layers of rip stop nylon at angles to each other both sides of the centre layer both ends. • When this was in place the outer foam layers were glued on sealing and forming the blank 2D shape. • After cutting these out the sides to be internal were roughed up with a

Page 32 Praying Mantis Knives

to improve gluing. • After marking the blade edges the form was carved with a power tool. The hilt/handles rounded to be ergonomical, the edges sharpened off. • Having dusted then and heating the outer layer then pressing it smooth initial layers of acrylic paint and latex mix are painted on. After about 8 layers the decorative elements are painted on.

Page 33 Praying Mantis Knives

• The final element is the grip added to the handle, glue and wrapping it into place. Velvet was used for aesthetics but with hind sight this should have been leather or rubber tennis racquet grip. • Finally the rubber sections were sprayed with silicon dashboard/back to Black polish to loose the grip on the latex surface and add a shine.

Photos taken from my film extra / supporting artist/modelling portfolio .

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