Manufacturing razor blades

1. A method of manufacturing razor blades from a strip material having upper and lower surfaces, a maximum thickness, and lengthwise-extending edge regions that are converted to blade edges during the method, the method comprising the steps of:

(a) providing the strip material;

(b) contacting the upper and lower surfaces of the strip of material with a first set of rollers to reduce the maximum thickness of the strip material by at least 10% and to roll down the material at locations to provide beveled surfaces in the upper and lower surfaces at the lengthwise extending edge regions of the strip material, wherein the beveled surfaces have a thickness which is less than the maximum thickness;

(c) contacting the upper and lower surfaces of the strip of material with a second set of rollers to reduce the maximum thickness of the strip material by an additional amount and to offset the material at locations with the beveled surfaces at the lengthwise extending edge regions placed in between the offsets;

(d) contacting the upper and lower surfaces of the strip material with a third set of rollers to reduce the maximum thickness of the strip material by an additional amount and to flatten the offsets and provide weakened regions;

(e) separating the strip material lengthwise between the beveled surfaces and the weakened regions; and

(f) sharpening the beveled surfaces to provide blade edges.

2. The method of claim 1 , wherein during step (b) the maximum thickness of the strip material is reduced by at least 20%.

3. The method of claim 1 , wherein during step (c) the maximum thickness of the strip material is reduced by at least 30%.

4. The method of claim 1 , wherein during step (d) the maximum thickness of the strip material is reduced by at least 40%.

5. The method of claim 1 , wherein step (b) is carried out with the strip material moving in the lengthwise direction on a processing line and the strip material is under tension in the lengthwise direction prior to step (b), and wherein the tension is reduced during steps (b), (c), and (d) as a result of the reduction in maximum thickness of the strip material, the method further comprising adjusting the tension on the strip material after step (b).

6. The method of claim 1 , wherein the offsets are flattened at least 50% during step (d).

7. The method of claim 1 , wherein the strip material comprises stainless steel.