The Serrata Process

Serrata…after the Latin word for “little teeth.”

The Serrata Project was started by myself after seeing and understanding what David Boye did in investment casting in the 80s and 90s with his 440C steel knives.

He found that the steel formed a dentritic structure, and the edge of the knife exhibited a “toothy” composition, and cut more aggressively than hot rolled 440C steel when merely stock removed as in a normal grinding process to make a knife.

I researched and worked out how to do the casting, and after a few tests, Serratas were made and sold around the globe.

( I actually have made 125 blanks in November 2017 and am slowly working my way through finsishing them ready for sale )

For details about the Spyderc  Serrata initiative please see here.

The process by which I made the Serrata.

Step 1: Make a model of the knife.

Step 2: Make a re-usable mold of the knife.

Step 3: Pour liquid molding wax into the mold.

Step 4 : When the wax has cooled, open the mold and remove the wax blank, and check for defects, and remake the wax blank if neccesary.

Step 5: Make the correct amount of wax blanks, and join together with cylinders and blocks of wax to create a “tree.”

Step 6: Coat the wax tree with different layers of ceramic slurry, and leave to set for a period of time.

This is the ceramic shell, which has been molded around wax copies of the knife.


Step 7: Heat up the ceramic shell and this fires the shell, and melts out the wax.

It is glows with a reddish tinge as it is removed form the firing oven.

Step 8: Make sure that the shell is steady and secure on a bed of sand. Spilled liquid steel has a way of ruining your day.


Melting 440 C steel in a furnace.

Step 9: Pour the liquid steel into the shell

Step 10: Let the steel cool overnight.

When you break off the ceramic  shell off with hammers and brute force, this the result.

The top knives have had the sprues removed, and the knife below is ready for use. The heat treatment of the Serratas is a propriety method of heat treat. I do have some secrets, folks.

Green canvas Micarta, stainless steel Corby bolts, and a Kydex sheath. Ready to slice and dice.

In 2013, Spyderco approached me to licence my design…. See Spyderco Serrata Prototype.