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American Made Nail Clippers
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Patriot Edge
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American Made Nail Clippers - Patriot Edge
In February, 2010 I was trying to clip my toenails and, as usual, struggled to get the nail between the jaws. So I thought, “Why don’t they make clippers that curve like my nails?” After not finding what I wanted on the Web started thinking through everything it would take to make a pair like I wanted. Little did I know I was embarking on a fascinating education in metallurgy and manufacturing. As an electrical engineer and programmer, I was not perfectly prepared for this endeavor. But I did have a couple years experience using a small milling machine. That proved invaluable.
Then I learned how to use Rhinoceros, a great little CAD program. And with that, was able to find the geometric secret of matching compound curves. OK, fine. What kind of steel should I use?
Most clippers use steel that can be hardened but to avoid corrosion they must be nickel or chrome plated. I’m guessing 1018 spring steel. At least that’s what I would try first if I didn’t mind the plating process. Besides there being few plating companies in my area of Huntsville, Al. I also didn’t want the added expense of developing a plating process and having to deal with the EPA and who knows how many environmental organizations. So stainless steel seemed to fit my needs. It comes in 2 grades, 300 and 400 series. The 400 series can be hardened through heat treatment.
In trying 410, I could punch and shape it but the welding process was nearly impossible with a spot welder. Then I tried 440C. Cold forming was impossible. So that left the 300 series.
Tried 304 and 316. Both formed well, machined well and welded fine. But the sharp edge just didn’t last. The steel was too soft. Then I found 301. It has the highest work hardening rate of any stainless steel. And I could order it pre hardened. It comes in 4 harnesses: 1/4, 1/2, 3/4, and Full. Tried the 1/4 (RC25). It worked ok but the edge still felt a little soft.
Then tried 1/2 (RC32) and the edge felt about right but the forming and punching was getting more difficult, do-able, but difficult. I had to be sure my shaping and sharpening process was getting me at least RC40. So I had a micro-hardness test done and the results blew me away. My first test yielded RC59! Subsequent tests yielded around RC55 and never went below RC50.
My first working pair were made in December, 2010. Eight months after I began.
So far, in 2011, I’ve redesigned the clipper and all the fixtures and tooling necessary for low rate production. Quality control is being implemented throughout the process to increase yield and lower costs.
Thank you for your interest in how this got started.
Sincerely,
Willie Maddox
Patriot Edge
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