The Pen-Making Process: A Technical Look
Every pen I create begins with the careful selection of materials. I start by choosing a blank, whether acrylic, wood, or a hybrid material, based on its grain, colour, figure, and overall character. The material plays a major role in determining not only the pen's appearance but also the experience of owning and using it.
Once the blank has been chosen, I select the pen style and fittings that will best complement its unique qualities. Whether it becomes a fountain pen, rollerball, or ballpoint, every decision is made to create a balanced, attractive writing instrument that showcases the beauty of the material and a pen that will be treasured.
Drillling & Turning
The blank is then drilled using a precision drill press to accommodate the correct brass tube for the pen mechanism. I use a wide variety of drill sizes, depending on the kit specification, to ensure the hole is clean, central, and accurate. The brass tube is inserted using a two-part epoxy or CA glue to provide a secure bond, then left to cure, often for several hours.
Once cured, I trim the ends of the blank flush to the brass tube using a barrel trimmer. Sometimes, I put them on a lathe. This ensures a perfect fit with the hardware components and eliminates blowout risks during the turning process.
The blank is then mounted onto a lathe between bushings matched to the pen kit. Turning is done with sharp carbide or high-speed steel tools, refining the blank to a balanced and ergonomic profile while maintaining clean transitions at the bushing lines.
I decide when turning whether to create a profile or a straight pen. The patterns tell me what they want to be.
Resin Finishing
Sanding is a critical part of the process. I dry sand by hand, starting at 320 grit and moving through 400, 600, 1000, 3000, 5000, and finishing at 7000 grit. This progressive micro-abrasion removes tool marks and gradually polishes the surface.
To complete the finish, I apply a high-quality plastic polish, buffed in gently by hand or at low lathe speed. This not only enhances clarity and gloss, especially in acrylics, but also provides a durable, tactile finish that resists micro-scratches and brings out the material’s full visual depth.
Before assembly, I run the polished ends of the pen part on as piece of fine sandpaper to remove any polish residue and the ensure the end is clean, then I use a drill with a polishing mop to remove and burr created.
The result is a precision-crafted writing instrument, one that’s as rewarding to use as it is to admire.