I guess I will. I only caught up with this thread the other day. Has a die sinking EDM process been considered for the lock portion of manufacturing the knife?
I have only seen pictures and descriptions of the Appleton's lock mechanisms, but as I understand it, in principle there something like a gear cut into the blade with a mating one cut into the button and a ball bearing which locks both together when engaged. I'm quite sure I'm missing out on critical aspects of the lock design, but I hope I have the basic principle correct.
Anyway, I know that the equivalent of cutting internal gear teeth - particularly if they don't go all the way through the stock can be a manufacturing nightmare. However, within certain limits, this can be where a die sinking EDM process can shine. The important aspect is that the die can be virtually any shape that you can plunge directly down into the material. Obviously, the precision of the die becomes incredibly critical at this point, but you only need to make one of those.
Granted, this is still relatively expensive as a way to go, but with volume maybe the economics would work out.
If you researched wire EDM, I imagine that you must have at least looked at the possibility of die sinking, but I thought I would mention it just in case. I've had to figure out how to manufacture alot of weird things in my career (I'm a mechanical engineer that pretty much has spent all of his career in manufacturing) and had actually thought about how to manufacture one of Ray's knives sort of as an exercise after reading a magazine article around it.
Anyway - just call me one of the many Appleton fans out there who finds many of the knives extremely elegant, and functionally novel in a landscape of knives which often times isn't. Unfortunately, you can also call me one of those Appleton fans that has never really had a chance to handle one close up and buy one, and is wistfully hoping someone can figure out how to manufacture one in quantity that is still good quality. (I saw a copy in a knife shop once which really was not impressive at all - I don't remember who made it, but vaguely remember that it might have been chinese)