Building high-quality prototypes required us to design a number of custom tools, including a bridge saw and specialized jigs. Follow our process to cut carefully measured guide slots into PVC pipe to create a prototype slicing guide.
Cutting the Lettuce Gizmo® Cylinder Blank
Rounding the inner and outer edges of the cylinder blank’s ends
Side view of our custom bridge saw
Mounting the cylinder blank into the bridge saw
Aligning the PVC pipe blank in preparation for machining
Close-up view of machining a prototype
Prototype Slicing Guide after slots have been cut
Auxiliary View of the prototype
Top-down view of a 5×5 prototype. The final design (4×4) is shown below
Top view, angled forward
We designed a custom knife that would be compatible with our Slicing Guide. We cut and sharpened blanks from cutlery-grade steel, around which we molded high-quality resin handles. These low-volume prototypes were to be duplicated by a knife manufacturer during the full-volume production run, but since that time we have located a suitable commercially available knife and will be using it instead.
Knife
Rough-cutting the knife blank
Final shaping of the knife blank
Grinding the 20-degree beveled edges onto the blade