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While we heartily approve of our Armed Forces wearing dress swords and sabers, we thought it was a shame that only unsharpened, poorly tempered wall hangers made of weak stainless steel are all that's available. That' why Cold Steel decided to make their own truly battle worthy reproductions. They're faithful in every detail to government specifications; they offer highly polished blades, appropriate etching and quality hilts and scabbards.
The only real changes Cold Steel has made are to drastically improve their performance as weapons by forging them from 1050 Carbon Steel and properly heat treating them to a tough spring temper before sharpening.
The daggers are approximately made as follows. The basic shape of the blade is made by a laser CNC machine. It is burned from spring steel. The semi-finished blade follows then in the groove cutter, where the cutting edge and the groove are milled. The blade is then oil-quenched and tempered to the desired hardness. Then the guard and pommel is attached to the blade tang. The tang is usually peened at the end (behind the pommel) and the cross-guard hard soldered with brass. Hardwood plates are placed under the handle wrapping from genuine cowhide so that the handle is sufficiently robust for a safe grasp. The steels surfaces obtain the desired finish in the end - with a wire brush or with a felt disc with polishing paste.