On the Cutting Edge: The Making of the West’s Best Knives
See the craftsmanship that goes into every blade from New West KnifeWorks.
Corey Milligan founded New West KnifeWorks more than two decades ago, and there aren’t many chefs left to convert. Nor, it would appear, food writers. From The New York Times and The Wall Street Journal to Bon Appetit, Cooking Light, Food and Wine, and the shuttered Saveur, reviewers universally wax rhapsodic about the unique alloy of form and function that lies at the heart of each blade, the durable yet elegant handles; the near-impervious surgical steel.
But Sunset got there first, with a 2001 piece that Milligan credits with helping to launch his brand from part-time passion to full-time pursuit. “A good knife is the making of a cook,” we said then, while “a beautiful knife is a cook’s joy.” That era’s magazine design might not have aged well, but the statement—and New West KnifeWorks itself —remain solid.
To recognize the two decades Milligan has spent crafting American-made blades in the West, we headed out to the Tetons for a factory tour. First, however, we caught up with Milligan and his core team during a steep hike up the windy slope of Mount Glory, the pass that separates Wilson, Wyoming and Victor, Idaho, where New West’s headquarters is located.
“I think that was the worst weather we had all year,” Milligan recalls. Icy conditions and petit toe-holds conspired with gusts of wind and the flat surface area of an unlashed snowboard for an experience not unlike windsurfing up a hill of razor blades.
For Milligan, that summit is an essential part of honing his view of the world. It is an extension of his office, a dedication to the terrain; on some of his blade faces you’ll find the Tetons set in relief through a custom and proprietary process that we promised not to share here.
The indentation, like most things at New West, is a practical flourish, it helps release the suction-like grip on sliced tomatoes, onions, and other moist vegetables, preventing runaways from tumbling across the counter (and removing your focus from the blade). But it is also deeply artistic. Other brands slap a logo on it. New West puts theirs to work.
At the time of our visit, Milligan, the hard-working artist, craftsman, father, and businessman, had taken on a new role: pushing the local city council to acknowledge the dangers of the Coronavirus. While the speaker of the council admonished him, Milligan slowly swabbed and disinfected every part of the lectern he was to speak at, laboriously as if to prove a point.
It is a ritual we’ve all become accustomed to, now, but Milligan was just ahead of the curve. In fact, New West was one of the first businesses in the entire country to devote production efforts to creating hand sanitizer, an effort that was echoed by thousands of companies in the weeks that followed.
Now, with protocols in place, Milligan has his factory humming again, and remains optimistic.
Two decades in, and New West hasn’t lost its edge.
Why should you? In our video above, Milligan shows how to keep your knives honed; at the 2:48 mark you’ll see some bonus footage of his factory.
And scroll on to join us on a journey through Milligan’s inner sanctum.
Welcome to Knife Heaven
While Coronavirus concerns have closed the store for now, Milligan’s Victor headquarters is typically one of four retail locations including Park City, Utah; Jackson Hole; and St. Helena, CA.
Blade Polishing Flywheel
Being in business for more than two decades means New West has been able to refine not only their products, but their process. “We built this polishing [machine] ourselves—there just aren’t that many independent knifemakers out there,” says Milligan. We had to work with 3M directly to get the right abrasive material.”
Raw Materials
Handle stock is selected from a series of composite and natural materials that New West sources from the United States. The most exotic range from desert ironwood to brass-inlaid carbon fiber.
Rivets-in-Waiting
“There’s something to be said for high-tech meets low-tech,” says Milligan. Some aspects of knife making—like affixing handle stock to a blade—haven’t changed in hundreds of years.
Vintage Arbor Press
While New West recently invested in building a pneumatic rivet press, this stalwart press has helped assemble tens of thousands of knives.
Custom Engraving Station
In addition to New West branding, customers have an option of adding their personal branding to each blade. Look closely to see which celebrity is also a big fan of New West.
Handle Composites in Process
Through the years, New West has been able to invest in industrial machinery to help expand capacity. Here, a set of handle stock has been carved out by a CNC router, essentially a computer-controlled cutting tool.
Metal Handle Stock
New West’s newest line is a series of pocket knives that will cycle through various customized batches with special finishes and materials. Here, you see a range of knives in process.
Knives in Process
Petty knives are one of Milligan’s go-to knives for new customers because of their usefulness. Here, a series receives a final handle treatment.
Refurbished Cleavers
Two years ago, Milligan launched a refurbishing program for old cleavers, in most cases replacing handle stock but occasionally just delivering some light TLC and a fresh edge. “Why make it again when there are all of these amazing blades out there that just need some love”?
Serrated Knives
Milligan developed this particular wide-spaced serration with the godfather of the craft in Seki, Japan more than 20 years ago. The difference between this and your average bread knife: This one isn’t just sharper, it’s easier to sharpen thanks to the gentle curvature.
