While thinking about ways to manufacture the butter knives fast and efficiently, and also to maximize the use of wood and avoid waste as much as possible, I came up with a layout configuration that nested the knives together compactly. Each knife’s blade was tucked between the handles of its adjacent neighbors – both right and left. I reached for a hefty blank and drew on it the resawing patterns using a template (A). Then, after the knives were emancipated from their blank, I shaped the handles and blades to the design of my choice (B,C).
A. The staggered knives stacked right and left to each other. “x” is the minimum surplus of waste material. B. After the knives are resawn the couture of the blade and handle are drawn and then sawn off.
To exploit the potential of this method even further, I decided to drill a wide hole in the mahogany blank and rely on its perfect circular geometry in the design.