Would you start with Sketchup or on the bench?

[jtri]

I have decided to design and build some silverware maybe service for 8. (Do not tell my wife as there are so many other things I should be doing!) They are going to have wood handles and either silver or stainless steel blades. Lots of details to work out with the metal, but that is not my major issue at this time.
I started out drawing in sketchup but now I am rethinking my approach. As these need to feel and balance just right in your hand, I am thinking I want to carve them 1st to get what I want then either draw them or maybe 3d scan them, then clean up the scan on the computer.

So sketchUcation how would you approach this design problem? Bench 1st or Sketchup 1st?

Also does anyone have any experience with casting stainless steel for this application? There is a jewelry casting house that says they do this for utensils. I am skeptical.

Tahnks
Jeff

[Dave R]

I guess I would start at the bench. I'd make sure I have the metal bits first since the balance is going to be so critical. For your prototypes, start with something like basswood which is nice to carve. When you get the shapes you like make templates so you can reproduce the shapes. I think I'd expect every one of them to be slightly different, though. I'd make the templates to run along a follower on the bandsaw and make the blanks extra long on the end that will get the hole so you can attach the template to the blank. You'll probably want to drill the blanks before shaping so keep that in mind.

What kind of wood will the final handles be made of? What will you do the final shaping and smoothing with?

As for stainless steel eating utensils, I have a lot of experience with it. Casting stainless steel, not at all.

[jtri]

I have decided on finishing my sketchup models and meeting with a silversmith. Need to get a feel for the costs involved to see if this will go forward. I am also going to get a quote on casting them in stainless. If it is not outrageously costly then to then bench and then back to sketchup. Might 3d scan what I carve to get what I want into the computer. Lots to sort out to make this happen.
As for the wood not decided yet but the construction of the handles I am going to make 2 halves to go over the tang. The tang will be almost the full length of the wood then glue it all together with no rivets. I have done this with knives and like the results. As for this batch, if it goes ahead I will be rough carving the handles on a CNC.
Thanks
Jeff