Blade set, hair cutting appliance, and related manufacturing method

A method of manufacturing a blade set for a hair cutting appliance, comprising:

• manufacturing a stationary blade comprising the steps of:
• providing each of:
• a first sheet metal layer, said first layer comprising a substantially flat overall shape;
• a second layer;
• and
• an intermediate layer comprising:
• a region cutout from the intermediate layer, wherein said region cutout from the intermediate layer representing a cutout portion, wherein said cutout portion comprising:
• a first leg,
• a substantially parallel second leg, and
• a transition region between a first end of the first leg and a first end of the second leg;
• positioning the intermediate layer on the second layer;
• positioning the first sheet metal layer on the intermediate layer;
• deposing, and fixedly interconnecting, the first sheet metal layer, the second layer, and the intermediate layer thereby forming a segmented layered stack, wherein the first sheet metal layer and the second layer at least partially cover the cutout portion within the intermediate layer;
• forming, at a longitudinal end of the segmented layered stack, a leading edge;
• forming a guide slot defined by said transition region of the cutout portion within the intermediate layer, wherein the intermediate layer, at the leading edge, further comprises a plurality of residual end portions defined by the cutout portion;
• and
• forming, at the leading edge of the segmented layered stack, a plurality of projections alternating with respective slots, thereby defining a plurality of teeth and tooth spaces, respectively;
• providing a movable cutting blade comprising a toothed leading edge arranged to cooperate with the leading edge of the stationary blade;
• and
• inserting the movable cutting blade into the guide slot by passing the movable cutting blade through a lateral opening at a transverse end of the segmented layered stack.