1. Fire and steel: the art of forging
Our first glimpse into the workshop revealed one of the most captivating parts of traditional knife production: working with heated metal.
In the forge, pieces of steel are brought to a glowing temperature before being handled with long metal tongs. The intense orange and red light of the fire illuminates the tools and the surrounding workbench, creating a scene that feels almost unchanged by time.
At this stage, heat is essential. It makes the metal easier to shape under the hammer, allowing the craftsman to work the material into the desired form. Each movement must be controlled, and the temperature of the workpiece matters: the metal needs to be hot enough to forge effectively without being overheated.
The traditional Higonokami blade can also feature a layered construction known as warikomi. In this method, harder steel is enclosed within softer iron. The hard steel provides the cutting edge, while the surrounding material contributes support and resilience.
It is a clever solution to a fundamental challenge in blade-making: creating an edge that can become very sharp while retaining the toughness needed for practical use.
2. Shaping the metal: precision meets machinery
One of the most striking things about the factory was the combination of traditional handwork and industrial equipment.
In our photographs, we can see a substantial mechanical press fitted with specially shaped metal tooling. The craftsman positions a small metal component beneath the press, carefully aligning it before the machine performs its operation.
This is where repeatability becomes important. A knife may be simple in appearance, but its components must fit together correctly. The shape of the blade, the position of its pivot and the dimensions of the handle all influence how smoothly the finished knife opens, closes and feels in the hand.
The press helps form or work the metal consistently, while the craftsman's judgement ensures that each piece is correctly positioned and handled.
Watching this stage makes one thing clear: traditional craftsmanship does not mean rejecting machines. Instead, it means using the right tools while preserving the knowledge needed to make them work well.
3. From a blank to a blade
Once the metal has been shaped, the blade must be refined into its final form. This involves several operations, including further shaping, grinding and the preparation of the cutting edge.
The blade's outline is a defining feature of the Higonokami. Its relatively straight profile and simple geometry reflect the knife's practical origins. There is little unnecessary decoration in the design; the emphasis is on function.
The blade's distinctive chikiri, or thumb lever, is another important detail. It extends beyond the handle when the knife is folded, giving the user a place to press when opening the blade.
This small feature is more than a design flourish. It is central to the knife's operating principle, allowing the blade to pivot open without a spring-assisted mechanism or a modern locking system.
The simplicity of the design places considerable importance on the quality of the individual parts. The blade must be shaped correctly, the pivot must be positioned accurately, and the surfaces must be finished with care.
4. The final edge: grinding and sharpening
A blade does not become a good cutting tool simply because it has the correct shape. Its edge must be carefully ground, refined and sharpened.
We watched craftsmen working at rotating grinding wheels, guiding the blades against the abrasive surfaces with controlled movements. At this point, the work becomes especially dependent on experience.
Grinding removes material and establishes the blade's geometry. Sharpening refines the edge until it can cut effectively. Too much pressure, an incorrect angle or inconsistent movement can affect the result.
The craftsman must also pay attention to the finish of the blade. The goal is not merely to make the metal look polished, but to produce a functional cutting tool with the appropriate edge and surface quality.
There is something particularly satisfying about this stage. The roughness of the earlier operations gives way to cleaner lines and smoother surfaces, and the blade begins to look like the familiar Higonokami.
Yet even now, the knife is not finished. It still needs its handle and pivot assembly, followed by careful adjustment.
5. A handle built around simplicity
The classic Higonokami handle is made from a folded sheet of metal, traditionally brass or blackened iron, depending on the model.
Unlike many contemporary pocketknives, it does not rely on a complex arrangement of springs, screws and locking components. Instead, the blade pivots between the sides of the folded handle and is secured with a rivet.
This construction is part of the knife's enduring appeal. There are relatively few components to assemble, but the relationship between them matters enormously.
The blade must move freely enough to open and close, yet the pivot must provide sufficient friction for the knife to remain usable in its open position. The handle must also fit the blade without excessive play.
In our visit, we saw the workshop's production equipment alongside trays of small metal parts and finished components. These details offered a glimpse into the repetitive, practical side of manufacturing — the hundreds of small operations that transform raw materials into a consistent product.
6. Assembly: where everything comes together
Assembly is the moment when the separate elements become a complete knife.
The blade is placed inside the folded handle and secured at the pivot. The connection is formed by riveting, a process that requires control: the joint must be secure without making the blade too tight to move.
A well-adjusted Higonokami opens through the action of the thumb on the chikiri. When closed, the blade folds into the handle for convenient storage. When open, the user controls the blade through the handle and thumb lever rather than relying on a conventional locking mechanism.
That design has a particular character. It asks the user to understand the tool and operate it deliberately. It also explains why the fit and friction of the pivot are so important.
The final assembly is a reminder that a traditional craft is not defined only by dramatic moments at the forge. Much of its quality depends on subtle adjustments that may be almost invisible in the finished object.
7. Finishing by hand
The last stages bring together appearance, comfort and performance.
Our photographs show craftsmen working on blades at grinding and polishing equipment, with batches of completed metal components nearby. These operations help refine the surfaces and bring the individual pieces closer to the standard expected of the finished knife.
The final details matter. Edges need to be properly finished, the blade must move as intended, and the handle should feel comfortable and secure in the hand.
Traditional carbon-steel blades also require a little care from their owners. Unlike stainless steel, carbon steel can develop a patina and may rust if left wet. Wiping the blade dry after use and applying a light coat of protective oil helps preserve it.
For many enthusiasts, these changing surface characteristics are part of the attraction. A Higonokami is not designed to remain frozen in time; with use, it develops a character of its own.
More than a knife: a living craft
Perhaps the most memorable part of visiting Nagao Kanekoma was seeing how many different kinds of work coexist in one workshop. There is the heat and physicality of forging, the accuracy of machine operations, the concentration required for grinding, and the patience involved in final assembly.
Each stage calls for a different kind of skill. Some operations are dramatic and immediately visible; others are quiet, repetitive and easy to overlook. All contribute to the final result.
The Higonokami tradition began in the Miki area of Hyogo Prefecture in the late nineteenth century. Its popularity once spread throughout Japan, and the knife became a familiar everyday tool, valued for its simplicity and practicality. As mass-produced alternatives changed the market, the number of traditional makers declined.
Today, Nagao Kanekoma continues to preserve the Higonokami tradition, passing down techniques while developing new versions of the classic design. The company identifies itself as the sole maker authorised to use the Higonokami trademark.
That continuity gives the visit a significance beyond the manufacturing process itself. We were not simply watching a knife being made; we were witnessing a craft that has survived changing fashions, technologies and generations.
The beauty of making things well
A Higonokami is not an extravagant object. It has no elaborate locking mechanism, no complicated opening system and no need for unnecessary ornamentation.
Its beauty lies in the relationship between material, form and function.
After seeing the glowing steel, the heavy press, the grinding wheels and the careful work of the craftsmen, it becomes easier to appreciate what is hidden behind the knife's modest appearance. Every finished piece represents a sequence of decisions, movements and adjustments made by people who understand their materials.
The experience also offers a broader lesson about Japanese craftsmanship. Tradition is not simply the preservation of old objects or techniques in a museum. It is the continued practice of making useful things, refining familiar methods and passing practical knowledge to the next generation.
We left the factory with a deeper appreciation for the Higonokami — not just as a traditional Japanese pocketknife, but as a small object that carries more than a century of manufacturing history in its steel and folded-metal handle.
Sometimes, the most interesting things are the simplest ones. You just have to look closely enough to see how they are made.
