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Factory tour

Blades cutting and manufacture
It’s the first step of the production: here the pieces begin to be designed, which will made the knife. In our company, the production is manual.
In cutlery jargon, these pieces are named “supplies”.
Cutting is made thanks to cutters activated by hand, by one of our colleagues. The different shapes are made with molds. The cutting workshop allows us to transform raw materials of high quality: stainless 12C27 steel Sandwick (Sweden), carbon brass steel, nickel silver (upmarket alloy of copper and stainless).

During this first step, we get the beginnings of blades, bolsters, springs and bees.
After cutting, the hand-crafted manufacture of our items requires a great number of steps. The knife’s blade of a Laguiole closing knife totals up 20 steps of production.

Heat treatment

Blades and spring are heating in a oven functioning around 1652°F.
As soon as it’s removed from the oven, pieces are dipped into a cold oil bath.
The subtle blend of fire, air and oil gives to stainless a great resilience and elasticity.

Forge

Cutting and shaping of handles

Arbalète Genès David has its own horn shaping.
It’s hence one of the last defenders of this ancestral know-how.
We’re working, using carefully sawed raw horn by our “cacheur master” according to the handles’ lengths asked.
A cacheur is a craftsman specialized in the work of horn.
Moreover, horn plates are heating in a coal oven that softens the horn. This latter is then pressed in a mold that gives the special handle’s shape. After, the handle is routed and polished with a grindstone.
The result of this work gives a pressed horn handle, ready to be assemble.
Precious woods and noble materials as the solid horn, ivory or giraffe bone are shaped by our cutlery makers during the assembly.

Assembly

Traditional and hand-crafted fitting and assembly of your knife are made by hand, by only one person. On the contrary, steps of an industrial knife are repeated on an assembly-line or by a machine.
Each piece is unique since it’s made by the hand of our craftsmen.
As a case in point, a “3 pieces” Laguiole (blade, hallmark, corkscrew) requires 186 stages.
Platinum and springs are drilled by hand with delicacy.
For the sake of obtaining a precise fitting for each knife, our specialists prepare the platinum and spring with a file and a grindstone.
For an item with forged spring, our person who decorates puts all his knowledge for the fitting with the file, the blade, the spring and the bee, making a unique work. The blade’s back is decorated either by reel, or by file.
The handles are chosen for their quality and their aesthetics are fitted, drilled and adjusted. Our cutlery manufacturer will make fitting and nailing with high precision. Thus, your Arbalète Genès David knife is assembled in the old-fashioned style with rivets and not with industrial screws.

Ressuivage

The assembly, fitting, and finishing of your knife are controlled as much for its mechanism as for the esthetics: it’s the “ressuivage”.

Polishing

Polishing is the finishing stage of your knives’ blades: mat brushing, “varnished” polishing.
Our new process brushing/polishing gives a half-mat view, particularly aesthetic.
It’s the same thing for the bolsters. Concerning the handles, it’s polished depending on the materials used or the final result forecasted.

Grinding

Your knife’s blade is grinded with a mold by a specialized craftsman.
Wiping, control and package
Your knife is controlled once again, then cleaned up and wiped before being packed