Cheuk Yu • 2021 • Woodworking and Finishing
Rebuilt the handle of a utility knife using popsicle sticks
Custom-designed grip shape based on hand-fitting mockups
Surface coated with epoxy for protection and a smooth finish
Fully functional with original folding mechanism preserved
Popsicle sticks
Wood glue, Epoxy resin
Utility knife + rotary tool
Sandpaper, metal files
Adobe Illustrator (for sketches and ideation drawings)
This is a fully custom-fit, hand-shaped replacement handle for a folding utility knife, designed to specifically fit my hand. It was made using only popsicle sticks, wood glue and epoxy resin. This project aims to help improve the ergonomics of the original compact handle while retaining the full functionality of the folding and locking mechanisms. The shape of the new handle focuses on providing a more comfortable grip while holding the knife in both standard and pen grip. This addresses the discomfort caused by the original handle during long periods of use, especially when holding the knife in a pen grip.
Once the new handle is shaped into my desired shape, it is carefully sanded down and coated in epoxy resin for added durability and a smooth finish. The result is a significantly more comfortable grip that feels solid in use without compromising the knife's original function or purpose. While it wasn't made from very high-end materials or has a special finish, it has been a significant upgrade to a tool that I rely on for many of my projects. This is an example of how such basic materials can be crafted into something practical and functional.
A selection of process and final-stage photos that highlight the progression and detail of this project. From initial preliminary work to refined finishes, these images provide a closer look at the build and design journey.
(Full image gallery available on separate page.)