Manufacturing method for a stationary blade and stationary blade

A method of forming a sheet-metal based double-walled two-layer stationary blade for a blade set of a hair cutting appliance, the stationary blade comprising a first wall and a second wall that define therebetween a guide slot comprising at least one depressed guide recess arranged to slidably receive a movable cutter to enable relative lateral motion between the movable cutter and the stationary blade, wherein the first wall the second wall are jointly connected at a longitudinal end thereof, thereby forming a first and second plurality of stationary blade teeth that guard respective cutter teeth of the cutter, the stationary blade further comprising a tip defined by a transition zone between the first wall and the second wall, wherein when viewed in a plane that is perpendicular to the lateral direction, the teeth of the stationary blade comprises a U-shaped profile, wherein the first leg and second leg define respective arms of the U, and wherein the tip of the transition zone defines a bottom of the U that connects both arms,

• the method comprising:
• providing a first pre-product layer,
• providing a second pre-product layer which is separate from the first pre-product layer,
• providing guide slot between the first pre-product layer and the second pre-product layer, wherein at least one of the first pre-product layer and the second pre-product layer is either deformed or machined in a material-removing fashion, thereby forming at least one depressed guide recess that is arranged to receive the cutter, and that forms at least part of the guide slot, and
• bonding the first pre-product layer and the second pre-product layer at an offset from one another to form said guide slot such that the first pre-product layer and the second pre-product layer are arranged to jointly receive the movable cutter in said guide slot, wherein said bonding comprises depositing material at a transition zone bridging said offset and thereby forming said tips of the stationary blade teeth that connect the first pre-product layer and the second pre-product layer to one another,
• wherein the first pre-product layer and the second pre-product layer, in the bonded state, are at least partially offset from one another to provide a defined mating clearance fit for the cutter,
• wherein a first and a second longitudinal end of the first pre-product layer and a respective first and a second longitudinal end the second pre-product layer are bonded to one another such that the first and second plurality of stationary blade teeth are partially formed by the first pre-product layer and partially formed by the second pre-product layer, and
• wherein tips of the stationary blade teeth are arranged adjacent to a transition zone between the first pre-product layer and the second pre-product layer.