Material of knife handles

Handle Material

The choice of handle material significantly influences both the knife's design and its production cost. With the exception of injection-molded or metal handles, the production process for various materials follows a similar path. The selected handle material is cut into rectangular blocks that match the size of the final handle. These blocks are then shaped into the desired handle form, either by hand or with machines/robots and finally polished to achieve the desired surface texture and finish.

Natural wood and stabilization

Natural wood has long been a traditional and popular material for knife handles. Its natural grain and warmth provide a comfortable grip that many users appreciate. Wood comes in a variety of types, each with unique grain patterns, and can be dyed to achieve different color variations. Since every piece of wood has its own distinct grain, it gives each knife a unique and personal character.

However, as a natural material, wood is prone to movement depending on temperature and moisture levels. This can pose challenges, especially in full tang/riveted knives, where the metal tang and rivets may not shrink or expand at the same rate as the wood. Excessive shrinkage can expose the tang and rivets, creating uncomfortable burrs or, in extreme cases, lead to cracks in the handle.

One way to prevent reduce shrinkage is stabilizing the wood, which is especially helpful in case of wood with low density/high porosity. This is done by placing the block of wood into a vacuum chamber to extract the air from within the wood, and then introducing an acrylic resin into the wood. Afterwards, the scales are dried.

Stabilization not only eliminates movement, but also adds strength to the wood itself and makes it more resistant to rot. In most cases, it makes the handle look more attractive and still feels like wood in your hands, not plastic. The only downside of stabilization is cost.

natural wood

stabilized wood

Composite material

While natural wood is a popular choice for knife handles due to its warmth and aesthetic appeal, it can be expensive and prone to issues like movement due to moisture and temperature changes. To retain the look and feel of wood while making it more suitable for industrial-scale production, composite materials for knife handles were developed. There are different materials, with Pakkawood and Micarta (both registered trademarks) being by far the most popular ones.

Pakkawood:

Also sold under names like Staminawood, Colorwood, and Dymondwood, Pakkawood is a form of plywood. In the production process:

Moisture is removed from layers of wood veneer using a vacuum process.
The veneers are then bonded together with phenolic resins under high pressure, creating a durable, stable material.
Some layers are dyed with colored resins for a more natural or eclectic look.

This process results in handles that are much more stable, resistant, and largely waterproof compared to natural wood. Pakkawood comes in a range of base veneers and colors, but all share the signature layered look.

Pakkawood dynawood colorwood knife handle scale

Micarta:

In Micarta, the layers of wood veneer found in Pakkawood are replaced by paper or fabric, which are bonded together using phenolic resin and dyed in various colors. The most common types of Micarta used in knife handles are paper, linen and canvas Micarta.

Among these, linen Micarta is particularly popular due to its aesthetic similarity to Pakkawood. It provides a similar look while offering additional durability and stability. Since Micarta contains no wood, it is even more stable and resistant to environmental factors such as moisture and temperature changes than Pakkawood. This makes Micarta an excellent choice for knife handles.

Acryl

Acrylic handles are typically made from PMMA, a strong, durable, and highly resistant material. It is easily ground into shape and is known for its versatility in color and pattern, allowing for eclectic designsthat can make a knife stand out visually. However, acrylic handles are not cheap, and they are usually supplied in blocks that require shaping and polishing.

Recently, hybrid materials combining burl wood and acrylic resin have gained popularity in the market. These blocks are cast using dyed resin and natural burl wood, resulting in unique, visually striking designs. The production process is similar to that of stabilized wood.

knife handle scale burlwood stabilized and acrylic resin combination

Plastic

Plastic is the most commonly used material for mass-produced knife handles due to its durability, stability, and waterproof nature, making it suitable for dishwasher use.

In production, plastic handles are typically injection-molded into their final shape, either directly onto the knife's metal parts or as handle scales that are later attached to the tang.

In an industrial production, material as well as process costs are very low, making it by far the cheapest way of producing a knife handle. But as Expensive injection molds are required for, this method is only economical for large-scale production.

While plastic handles are highly functional, they tend to have a minimalist, utilitarian appearance, which some users may find less appealing.

Metal

Over the past two decades, knives with metal handles have gained popularity due to their seamless, one-piece construction, which offers a clean, hygienic, and durable appearance.

Knives with metal handles consist of two or three pieces. The most common method involves inserting a blade made of knife steel into a hollow handle made of stainless steel(formed by two welded scales). The blade and handle are welded together at the insertion point.

Some high-end full metal knives use a three-piece construction, where a hollow handle is welded to a solid bolster part, and this assembly is then welded to the blade. The advantage of this design is that the solid bolster improves the balance and strengthens the material structure near the welding seam.

Disadvantages of full metal knives are the risk or corrosion and breakage in the area of the welding seam (depending on production process), and the cold and slippery feel of the handle, which is disliked by some users.

Decorative elements

Twenty years ago, knives were largely seen as purely functional tools, with little focus on design. However, today’s knives have evolved into both practical and aesthetic objects, offering a wide array of handle shapes, materials, and styles. TTo further enhance the design, many knives now feature decorative elements, such as metal end caps, spacers, mosaic or logo pins, Blending different materials in one handle, such as wood, resin, or metal, to create unique and striking patterns.