Forging tools is one of the oldest skills known to man. Over the years there have been many changes in forging methods used to produce what is regarded as one of the foundations for everything - Hand Tools. Footprint operates five drop stamps at its factory in Sheffield to forge its core products - Wrenches, Tinsnips, Brick Bolsters & Cold Chisels, Hammers, Wood Chisels and Line Pins.

After a tool is forged it is far from ready for use and detailed over the next few pages is a broad overview of the processes that have in some form or another been used by generations of skilled Craftsmen - (also known as Sheffielders!) - to produce quality tools. It is because of these skilled Craftsmen that the term "Made in Sheffield" is known throughout the world as a sign of quality.

The first step in producing many of Footprint's products is to spark erode a pair of die blocks. The top and bottom die blocks have impressions spark eroded into them so that when the blocks meet, a forging of the shape is produced. Once the dies have been sunk the first quality check is made. A lead impression of the die is formed and checked to ensure the impression is of the right standard before forging. At this stage the die blocks are machined to allow the scrap steel to flow away from the impression and the cutting tools put on.

All Footprint products are heat treated to produce strong edges on blades, teeth on Wrenches or striking faces on hammers. Pictured is the hardening of the two striking faces of a Joiners Hammer. The Hammer is reheated in a furnace to over 800°c, removed from the furnace and placed in a jig exposing the striking surfaces, where it is squirted at high speed with a water based solution. It is then quenched in oil and tempered to ensure a fine grain structure is achieved through the steel.

After forging and hardening, products are in a "rough" state and still require much work to them before the are ready for use. Much of this is done on machinery however for some products the human eye is still the best way to produce the finest quality product. The picture below shows hand glazing (grinding) a tinsnip.

Over the years much of the traditional Wood Chisel hand grinding has given way to the much more efficient machine grinding. All Footprint Wood Chisels are forged as Firmer and then ground to form the more popular Bevel Edge blade. Pictured here is the machine grinding of the Neck of a wood chisel. Also pictured is a jig of Wood Chisels ready to have the top and bottom of the blade "Flatted".

It is at this stage that the products are ready for the final stages of production. Depending upon what the product is this could be assembled to handles or painting followed up by further glazing work. Pictured is the Paint Shop where you can see Brick Bolsters being dipped in paint and then sent through driers. Also shown is glazing the cutting edge on a Brick Bolster.

We hope you have found this brief tour of the factory interesting and please visit us again for news on new products and further information on how we manufacture quality tools.