Our disruptive blade manufacturing technology consists in a new roll forming process that uses tapered rolls to locally severely plastically deform a strip of material. The cumulative deformation imparted during the process produces both the final desired shape – a blade – and microstructural modifications in the material that provide high strength and hardness, and improved resistance to chipping.

Upon rolling, the cross-section of the strip changes from rectangular to an hourglass shape, until it splits into two independent blades. This process creates a gradient microstructure from bulk to tip, resulting in a flexible body of the blade and a strong sharp tip thanks to the fine microstructure that makes it homogeneous.

The chip-resistance has been shown through comparison videos of cutting experiments using both commercial razor blades and the ones made with our process.