Why American CNC Milling Produces Better Knife Fit and Finish | THE SHED KNIVES BLOG #104

December 20, 2025

CNC-machined fixed blade tang and G-10 scale fit

Speed Was the Problem. Precision Became the Solution.

For years, Shed Knives relied on an outside waterjet company to produce blade blanks. On paper, that made sense. In practice, it nearly capped the business.

Here’s what the process actually looked like:

Up to 3 weeks before an order was even started
1 week for cutting
Up to 1 additional week for delivery

That meant a single batch of blade blanks could take 5 weeks or more before it even touched my hands. Because I had to wait for knives to sell before placing another order, I could realistically only run about 12 batches per year.

That was the bottleneck.

Not creativity.
Not demand.
Not work ethic.

Time.

In the winter of 2024, I brought a Tormach 770M CNC mill into the Shed Knives shop. That decision fundamentally changed how our knives are made, how consistent they are, and why their fit and finish now stand apart.

This article explains exactly why American CNC milling produces better knife fit and finish, how we use it at Shed Knives, and what that actually means for campers, bushcrafters, and EDC users who depend on their gear.

What Production Looked Like Before CNC

Before CNC, almost everything was manual or outsourced.

Blade blanks were waterjet cut
Blade grinding was done by hand
G-10 scales were:
- Drawn by hand
- Cut by hand
- Ground and sanded by hand
Final assembly was manual, with tolerances depending entirely on human consistency

This approach works at very small scale, but it introduces variability at every step. It also consumes time at a rate that is impossible to scale without compromising quality or burning out the maker.

Waterjet cutting was the biggest technical limitation.

Waterjets do not cut straight. They introduce taper as the stream loses energy through the material. Industry data shows waterjet taper commonly ranges from 0.003–0.010 inches, depending on material thickness and feed rate (SME Manufacturing Reference).

That taper directly affects:

Hole alignment
Tang geometry
Scale fit

Those issues cannot be fully corrected after the fact, no matter how skilled the hand work is.

Bringing CNC In-House: Winter 2024

In winter 2024, I brought the Tormach 770M CNC mill into the Shed Knives shop.

That single machine replaced:

Blank profiling
Blade grinding operations
G-10 scale milling
Kydex sheath production

Everything now references a single work coordinate system (WCS). That matters more than most people realize.

A CNC machine does not “eyeball” fit. Every feature is referenced from a fixed zero point. Once that zero is set, every cut, hole, and contour relates back to that same origin.

That is how consistency is enforced.

The Tradeoff: One Machine, Higher Standards

There is a real risk when multiple processes depend on one CNC machine. If that machine goes down, production stops.

The solution is not fear. The solution is discipline.

CNC requires:

Preventative maintenance
Tooling management
Calibration checks
Clean setups

You do not get consistency by accident. You earn it through attention to detail.

As long as the machine is maintained, it remains reliable for as long as we want to make knives.

Where Fit and Finish Actually Improved

1. Scale-to-Tang Fit (The Most Important One)

This is the area I care about most.

Scale-to-tang fit determines:

Comfort during long use
Whether hot spots develop
Whether debris and moisture collect at seams

With CNC milling, both the tang and the scales are cut from the same digital reference. That eliminates cumulative error.

Even on a CNC machine, you can still mess this up if your programming or setups are sloppy. Precision demands competence, not just equipment.

2. Hole Alignment

Before CNC:

Holes were waterjet cut
Waterjets introduce taper and misalignment

Now:

Holes are drilled using ⅛-inch or ¼-inch drill bits
Holes are perpendicular and repeatable

That improves fastener seating, structural integrity, and long-term durability.

3. Symmetry and Edge Consistency

All blade geometry is now controlled to 0.003 millimeter tolerances.

That level of repeatability ensures:

Balanced grinds
Predictable edge geometry
Consistent sharpening behavior

Symmetry is not about looks alone. It affects how a knife tracks through material.

Reject Rates: Real Numbers

Before CNC, reject and rework rates sat around 10–15%.

Today, that number is closer to 5%.

That reduction matters because:

Fewer knives are compromised
More time is spent producing sellable inventory
Quality stays consistent batch to batch

Lower reject rates are not about profit alone. They are a direct indicator of process control.

CNC Is Not About Speed. It Is About Repeatability.

There is a misconception that CNC exists to rush production.

That is incorrect.

CNC exists to enforce repeatability.

Speed is a byproduct when the process is correct.

Quality comes first. Always.

If you can achieve quality and speed at the same time, that is ideal. If you have to choose, quality wins every time.

Why American CNC Milling Matters

American CNC milling is not better because of geography. It is better because of culture.

At Shed Knives, American manufacturing means:

Direct accountability
Clear communication
Immediate feedback loops
A culture focused on doing the right thing every time

In overseas mass production environments, quality is often defined by acceptable failure rates. In this shop, quality is defined by whether I would carry the knife myself.

That difference shows up in tolerances, finishing, and final inspection.

What This Means for the User

Better fit and finish is not cosmetic.

It means:

Fewer hot spots during extended use
Safer handling under load
Better grip transitions
Higher confidence in the tool

A knife that feels right in the hand encourages correct use. That matters in camp, in the field, and in daily carry.

The Investment Behind the Results

The CNC machine and required specifications cost approximately $23,000.

Setup took about two weeks.

The learning curve took roughly nine months.

All of 2024 was largely spent learning how to extract real precision from the machine.

CNC does not shortcut mastery. It demands it.

Why CNC Milling Matters at Shed Knives

CNC milling matters at Shed Knives because it enforces and requires consistency in production.

Consistency is what allows:

Reliable fit
Predictable performance
Trust from the user

That is the standard we build to.

Final Thoughts

American CNC milling is not marketing fluff. It is a commitment to precision, accountability, and performance.

At Shed Knives, CNC is not about replacing craftsmanship. It is about protecting it.

When you pick up one of our fixed blades, what you feel is not chance. It is the result of controlled processes, tight tolerances, and a refusal to accept variability.

That is how trust is built & quality held to the highest of levels.

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Explore the 2026 Skur here: https://shedknives.com/products/2026-skur

Know another outdoor enthusiast who may find value in this blog? Feel free to share the link of this blog with them so we can continue to educate & encourage our fellow outdoor & knife enthusiasts. Thank you for your support. - WJB

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About The Author:

W. Jack Billings - CEO & Founder, Shed Knives shedknives.com

Jack Billings is the 21 year old CEO and Founder of Shed Knives, a rising manufacturer of high-quality fixed blade bushcraft knives. With over 5 years of experience as a knife maker, he has developed a reputation for crafting durable, reliable knives that are designed for outdoor enthusiasts and bushcrafters alike. Jack started making knives at the age of 13 and has been refining his craft ever since.

In addition to his expertise in knife making, Jack has a High School Degree from POLYTECH High School, where he studied Automotive Technology and obtained his ASE Certification. He is also a content creator for Shed Knives and has reached the eyes of over 1,000,000 people on Shed Knives platforms across the world through his work.

When he's not working on knives, Jack enjoys exploring the outdoors and has a passion for bushcraft. He also has a passion for the automotive world and enjoys learning about new technologies and advancements. Additionally, he has a great interest in language and is studying Spanish, German, Russian, and Arabic.

Jack's personal mission is to constantly improve himself, his products, and his processes in order to stay ahead of the rapidly changing interests of the knife industry and to surpass the competition. He takes great pride in American manufacturing and is committed to contributing to the growth of the world knife industry through his work.

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