Every Benchmade knife is assembled by hand, and it’s no surprise that there are more hand operations performed at this point in a knife’s production than at any other stage in the process. An assembly technician receives all of the components — blade, liner, handle, hardware — and carefully pieces them together. The technician checks the knife for blade play (movement from side-to-side and up-and-down), and the result is a knife just waiting to be sharpened.
It takes longer to master blade sharpening than any other skill. A sharpening technician puts a razor edge on the knife using a standing belt sander, and this step takes extraordinary concentration. Each blade is sharpened to a targeted 30-degree inclusive angle, 15 degrees on each side. The knife is sharp enough when it can cut through ultra-thin phonebook paper effortlessly without tearing. And only then is it truly a Benchmade.
There are up to 35 different people who handle the materials for manufacturing and building a single knife.
This is how much raw material we use in a year to make our knives:
Steel - 179,000 LBS — Enough to build almost 60 SUVs
Titanium - 3,100 LBS — Enough to make more than seven exotic racing motorcycles
Aluminum - 438,000 INCHES — Longer than 121 football fields
Carbon Fiber - 153,000 square feet — 3.5 acres