Behind The Design

Our Process

The Oyster Knife, Redefined

We didn’t set out to make just another oyster knife, we set out to rethink the process entirely. That meant spending time in the field, observing different ways oysters are shucked and where things go wrong. From hands-on testing to ergonomic studies, from blade analysis to countless prototypes, every step pushed the design forward. What you’ll see below is the process we followed, driven by research, refined through iteration, and always grounded in real-world use.

Shucking is Hard

From oyster grants to raw bars, we’ve spent time on both sides of the shell. And here’s the truth: shucking is hard. It takes strength, technique, and patience. When we started Outer Cape Kitchen, our goal was to design a better oyster knife—one that makes shucking safer, more intuitive, and just a little more enjoyable.

Ergonomics Study

Every tool's foundation starts with ergonomics. Testing revealed two key pain points. First (1), to get leverage, shuckers often hunch into a “chicken wing” stance, where the elbow is cocked high, engaging the shoulder and back unnecessarily. Over time, that strain adds up. Second (2), a lot of force is focused on the tip of the oyster. If the blade slips or the shell cracks, injuries happen fast.

Blade Study

Through testing, we evaluated a couple dozen oyster knives, each with a different tip shape. This revealed two key insights: different oysters can require different knives, and there’s no single ideal blade - multiple shapes can get the job done. We grouped them into two types: pointed and rounded. Pointed blades are fast and efficient but sharper and hazardous . Rounded blades are better for side shucking but less effective at tackling the hinge.

Concept Development

Sketching is when key insights and ideas are visually communicated. Starting with quick doodles, sketches grow, transfer and spawn into new ideas that over time mature into chosen concepts to be further developed.

In CAD, 2D sketches are transformed into 3D models. Initially concepts are quick and dirty to test out concepts but over time details, curvatures, surfaces are refine.

3D printed object on a textured PEI plate with grid lines

3D Printing

3D printing transforms concepts into tangible prototypes by layering materials, such as filament, to build objects from the ground up. This additive manufacturing process enables rapid creation of prototypes for testing and evaluation. At each stage, feedback informs adjustments, leading to multiple iterations that refine the design. Through this cyclical process, the most promising ideas are identified and developed further with the manufacturer, where the refinement process continues.

From Final Tweaks to Final Product

Once the design was locked, we worked closely with our manufacturer to fine-tune the details. We tested finish options, honed the blade profile, and dialed in the tolerances until everything felt right in hand. The result is a knife that balances performance and durability, built for the long haul whether you're behind the raw bar or shucking at home.