Podcast
Edge & Flow Podcast
Edge & Flow Podcast is a joint effort between knife makers TJ Schwarz and Lucas Burnley, your hosts. Free flowing, unscripted conversations unfold as we endeavor to explore the knife industry, craftsmanship, business, creativity, and beyond.
- Design chart
- #53
- Episodes
- 109
- Releases
- Weekly
- Typical length
- 1 hr 10 min
- On air since
- 2022
- Latest episode
- 6 days ago
Episodes
109 episodes, newest first
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1 hr 2 min
EP 109 | Unfinished Ideas
Episode 109
Show notes
Were back! Lucas and TJ talk shop equipment, imported tools, manufacturing efficiency, and the never-ending process of optimizing a small shop. They also get into creativity, unfinished ideas, and why executing an idea matters more than just having one.
Check out the brands:
BRNLY: https://brnly.com
Instagram: @brnly_brand — https://www.instagram.com/brnly_brand/
Lucas Burnley Instagram: https://www.instagram.com/burnleyknives/
Schwarz Knives: https://www.schwarzknives.com/
Instagram: @knife.designer — https://www.instagram.com/knife.designer/
Follow Edge & Flow for more conversations on knife making, craftsmanship, and the creative process.
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1 hr 3 min
EP 108 | Are We Losing the Art of Making?
Episode 108
Show notes
Lucas and TJ are back for Episode 108 of Edge & Flow. This week they talk traditional knife making, CNC manufacturing, AI, new shop technology, and how modern tools are changing the way makers work. Plus, shop updates, laser tech, and the challenges of running a growing knife brand.
Check out the brands: BRNLY: https://brnly.com
Instagram: @brnly_brand — https://www.instagram.com/brnly_brand/
Lucas Burnley Instagram: https://www.instagram.com/burnleyknives/
Schwarz Knives: https://www.schwarzknives.com/
Instagram: @knife.designer — https://www.instagram.com/knife.designer/
Follow Edge & Flow for more conversations on knife making, craftsmanship, and the creative process.
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1 hr 21 min
EP 107 | Jonah Boatman, Dull Boy Blades
Episode 107
Show notes
Lucas and TJ are back for Episode 107 of Edge & Flow, with TJ fresh off Blade Show West! This week, they sit down with Jonah Boatman of Dull Boy Blades to talk about how he got into knife making, his journey building a knife brand, and what it takes to make a name for yourself in the knife industry.
- Schwarz Knives: https://www.schwarzknives.com/shop
- BRNLY: https://brnly.com
- Dull Boy Blades: https://dullboyblades.com/
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1 hr 32 min
EP 106 | Blade Show, CNC Machines & Electricians
Episode 106
Show notes
Lucas and TJ discuss preparing for Blade Show while moving into a new shop, keeping product drops on schedule, and setting up a more efficient manufacturing space. They also dive into CNC machining, ERP systems, and using AI to build smarter workflows and improve shop safety.
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59 min
EP 105 | New Shop Planning
Episode 105
Show notes
Lucas and TJ talk about the new shop, planning the layout, new machines, three-phase power, lasers, production, and everything that goes into building out a bigger manufacturing space.
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1 hr 19 min
EP 104 | Fish Camp, Shooting Comps & Hiring
Episode 104
Show notes
Lucas and TJ recap their experience at Work Sharp Fish Camp, talk about the value of building community, and share some thoughts on hiring, growing a team, and finding the right people. They also get into product development, making things for real-world use, and creating more space for good ideas.
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1 hr 6 min
EP 103 | Tacos, Marathons & Projects
Episode 103
Show notes
We're back! This week on Edge & Flow, TJ and Lucas answer listener questions, talk about building a stronger brand, staying consistent, and the challenges of creating a more efficient knife-making process.
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1 hr 6 min
EP 102 | AI, Road Trips & New Shop
Episode 102
Show notes
Lucas and TJ are back with another episode of Edge & Flow. This week they talk AI, building an ERP for the shop, manufacturing, custom orders, and how better systems can make more room for the things that actually matter.
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1 hr 35 min
EP 101 | Manufacturing, Scaling & Demand
Episode 101
Show notes
Lucas and TJ are back for Episode 101 of Edge & Flow. This week they dive into Enduro production, manufacturing efficiency, CNC machines, and scaling a small knife shop. They also discuss knife drops, online lotteries, and the challenges that come with having more demand than product.
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1 hr 30 min
EP100 | New Knives, New Shows, New Shops
Episode 100
Show notes
We're back! Luc and TJ discuss the many things that have happened in 2026 such as the launch of the Enduro, staffing changes, and a long list of knife shows.
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1 hr 1 min
2025 Wrapped
Episode 99
Show notes
Lucas and TJ reflected on their first year in their new shop, discussing their transition from a garage setup to a mature production company and highlighting their progress with various manufacturing processes. They explored the integration of forging and CNC machining techniques in knife making, while emphasizing the importance of learning from experienced manufacturers and accessing available resources for process improvement. The conversation concluded with discussions about industry trends, branding strategies, and the personal fulfillment found in creating unique knife designs, along with reflections on their business growth and future plans.
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1 hr 14 min
Fire Drill
Episode 98
Show notes
In this meeting, TJ and Lucas discussed a recent fire incident at a nearby bar and the importance of having business insurance, which TJ confirmed was in place for his shop. They reviewed their Thanksgiving holiday plans and Black Friday sales strategy, noting the success of their first-year discount promotion. The conversation then shifted to manufacturing topics, including Haas's equipment expansion, tool storage solutions, and various prototyping methods for knife-making, with particular focus on design processes, bevel grinding fixtures, and the importance of documentation and revision control in their work.
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1 hr 10 min
Value Proposition
Episode 97
Show notes
Lucas shared his hunting experiences and reflections on gear reliability, while comparing hunting to his work as a knife maker. TJ discussed fixture upgrades for knife models and manufacturing processes, including challenges with materials and vacuum forming techniques. The conversation concluded with discussions about documentation systems, project management tools, and the importance of aligning new product offerings with brand value propositions in the knife industry.
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1 hr 28 min
Folding Knife Development
Episode 96
Show notes
TJ and Lucas discussed TJ's journey in knife manufacturing, including his transition from fixed blades to folders and the challenges of prototype production and scaling operations. They explored strategies for diversifying TJ's business while maintaining his existing product line, with Lucas sharing insights on balancing growth and production efficiency. The conversation concluded with discussions about shop setup, including equipment purchases and layout changes, while touching on industry trends and market conditions in the knife industry.
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58 min
Fixing Machines and Choosing Air Compressors
Episode 95
Show notes
In this meeting, TJ and Lucas discussed their experiences at the Blade Show West and Lucas's plans to refocus on custom folders, while also addressing machine maintenance issues and tool life challenges. They explored various solutions for Lucas's shop, including air compressor options and the importance of understanding financial statements for business decisions. The conversation concluded with a discussion about the value of networking and seeking advice from experienced individuals to help grow their businesses.
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1 hr 19 min
Financial Structures of Knife Companies
Episode 94
Show notes
Lucas and TJ discussed the upcoming Blade Show West and its unique characteristics compared to other knife shows, emphasizing its value for newer collectors and employees seeking firsthand customer interaction experience. They explored various business aspects of the knife industry, including pricing strategies, market dynamics, and the challenges of scaling operations, while examining successful companies like Benchmade and Montana Knife. The conversation concluded with discussions about the industry's evolution, focusing on technological advancements, changing manufacturing processes, and the potential for new companies to emerge and succeed in the knife market.
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55 min
Fish Camp
Episode 93
Show notes
Lucas and TJ discuss a Worksharp sponsored salmon fishing trip and the importance of spending time with colleagues outside of a work environment.
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3 hr 4 min
Ernest Emerson
Episode 92
Show notes
Ernest Emerson shares his journey from martial arts enthusiast to renowned knife maker, detailing how his upbringing in Wisconsin, passion for functionality, and chance encounters with Navy SEALs shaped his career path from custom knife making to founding his own successful company. He discusses his business philosophy of treating employees like family, his approach to collaborations with major knife manufacturers, and his commitment to maintaining craftsmanship despite technological advances in the industry. Ernest also reveals his diversification strategy beyond knives, including apparel and whiskey businesses, while offering advice to aspiring entrepreneurs about full commitment, honest self-assessment, and maintaining ownership rather than seeking early investors.
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1 hr 10 min
Burnout
Episode 91
Show notes
The episode began with Lucas sharing his experience with burnout and his efforts to develop better self-care routines and work patterns, including using tools like ChatGPT to map out his workflow. Burnley and TJ discussed the challenges of balancing maintenance-focused work with creative projects in their businesses, with TJ sharing his realization about spending too much time on maintenance issues. The conversation concluded with a discussion about social media platforms, particularly Instagram and TikTok, including their evolving roles, decreasing engagement, and the impact of AI-generated content, as well as plans for shop organization and machine usage.
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1 hr 19 min
Coastal Adventures (PNWCI)
Episode 90
Show notes
Lucas and TJ return from a podcast hiatus. This episode is a recap of Pacific Northwest Custom Invitational as well as shop happenings over the last few months.
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