Recently I found some excellent knife blades which I’d typically saved – for probably twenty years! The original ‘French Ivory’ (i.e. early plastic) handles had long since cracked or shrunk and I’d thrown them away but I thought that I’d try making clay handles for the comfortable spreading blades. I still have one that I made back then, in earthenware, but it’s a little heavy and I got the length wrong.

BUT, my son Stephen has a new 3D printer, and he’s always interested in ideas for new creations (no, he never liked the idea of working with clay but he loves to fabricate his designs in metal or plastic. I have the very best clay cutter, and in my kitchen, a similar cheese knife).

https://www.gillianmcmillan.com/2014/02/05/cheese-cutter-for-clay-made-by-stephen-mcmillan/

I showed him my little collection of blades and within a week he’d designed and printed some jolly, red, ergonomic handles for them. Since I took the photo above I’ve glued the handles and blades together with Lepage’s 100 percent. They feel so comfortable and I shall be happy to have them join my other kitchen knives for spreading. No, I won’t be using them in my studio but I’m pleased that they will continue to be useful. And I shall not be putting them in the dishwasher.

He’s sent me some photos and a description of the process for those who might enjoy seeing how 3D printing works. Luckily for his students, this is a little part of what he teaches at BCIT.

The first two photos are of the printer. It’s an Afinia H480, printing in ABS plastic. The 1.75mm material is pushed through a 0.4mm hot nozzle, and deposited in layers 0.15mm thick. The total print for four parts took about 5 hours.

Later I used a process called acetone vapour smoothing. I used a low heat in the glass chamber, with a lid, until it was full of the vapour which is heavier than air. I fashioned a little tool to hold all the handles together, then removed the lid, and lowered them in for about 20 seconds. Then I let them air dry for a few hours.

Stephen McMillan

Thanks Steve!