Abstract: A method for manufacturing hand tools, such as wrenches. The method generally includes the steps of providing a flat stock, cutting the flat stock into the desired two-dimension blank using a laser, and three-dimensionally machining the laser-cut 2D blank into the desired three-dimensional workpiece. The tool may undergo a heating treatment process and a surface treatment process. In the context of a wrench, the blank may be laser cut with a laser beam oriented to cut generally perpendicularly to the plane of the flat stock. After laser cutting, the handle and interface region between the handle and jaw(s) are machined to provide the desired three-dimensional shape. For example, the three-dimensional shape may be selected to provide a comfortable grip even when applying a high level of force. The wrench jaw may have an optimized geometry calculated so that there is no excess material or “over-designed” regions of the jaw. The wrench jaw has internal corners with optimized radii.

Abstract: A method for manufacturing hand tools, such as wrenches. The method generally includes the steps of providing a flat stock, cutting the flat stock into the desired two-dimension blank using a laser, and three-dimensionally machining the laser-cut 2D blank into the desired three-dimensional workpiece. The tool may undergo a heating treatment process and a surface treatment process. In the context of a wrench, the blank may be laser cut with a laser beam oriented to cut generally perpendicularly to the plane of the flat stock. After laser cutting, the handle and interface region between the handle and jaw(s) are machined to provide the desired three-dimensional shape. For example, the three-dimensional shape may be selected to provide a comfortable grip even when applying a high level of force. The wrench jaw may have an optimized geometry calculated so that there is no excess material or “over-designed” regions of the jaw. The wrench jaw has internal corners with optimized radii.

Abstract: A method for manufacturing hand tools, such as wrenches. The method generally includes the steps of providing a flat stock, cutting the flat stock into the desired two-dimension blank using a laser, and three-dimensionally machining the laser-cut 2D blank into the desired three-dimensional workpiece. The tool may undergo a heating treatment process and a surface treatment process. In the context of a wrench, the blank may be laser cut with a laser beam oriented to cut generally perpendicularly to the plane of the flat stock. After laser cutting, the handle and interface region between the handle and jaw(s) are machined to provide the desired three-dimensional shape. For example, the three-dimensional shape may be selected to provide a comfortable grip even when applying a high level of force. The wrench jaw may have an optimized geometry calculated so that there is no excess material or “over-designed” regions of the jaw. The wrench jaw has internal corners with optimized radii.

Abstract: A screwdriver handle configured to provide optimal performance when used in certain handholds to provide high-torque turning with two hands, normal turning with a single hand or low-torque, repetitive turning with two hands. The handle includes a forward zone that is generally circular in cross-section, a central zone that is generally triangular in cross section and has an arrangement of progressive stepped regions and a rear zone that combines a generally cylindrical region with a domed end. The forward zone may in profile follow a shallow somewhat hourglass-like shape. The central zone includes at least two stepped regions that generally increase in diameter toward the rear of the handle. The rear stepped region may be convex having an apex forward of the rear zone. The generally cylindrical region of the rear zone may taper down toward the rear of the handle. The domed end may be a semi-spherical dome.