Method of manufacturing inner blade for electric razor

A method of fabricating an inner cutter for a dry shaver, said inner cutter having a number of blades in shearing engagement with an outer cutter for cutting hairs, said method comprising:

• providing a flat metal plate having a length and a width;
• forming a plurality of parallel straight slits in said plate to leave an array of straight beams each defined between the adjacent ones of said straight slits, and to leave a frame around the array of said straight beams;
• forging and grinding at least a segment of said beams to give cutting edges extending along said segment;
• bending said metal plate into a generally U-shaped configuration so as to correspondingly curve said beams and shape said segments into said blades each having an arcuate contour and said cutting edges extending along said arcuate contour;
• and
• forming on said frame a joint for connection with a driving source of moving said inner cutter relative to said outer cutter,
• wherein
• said metal plate is bent into said generally U-shaped configuration prior to forming said cutting edges, and said cutting edges of each segment are formed through:
• placing the U-shaped metal plate between a die and a punch;
• forging said segments simultaneously by compacting the segments between said die and said punch to form on opposite undersurfaces of each segment rake faces oriented at an acute angle with respect to a top surface of said metal plate, allowing a formation of bulge on top of said segment;
• and
• grinding said metal plate to remove said bulges in order to leave on top of said segment a relief face which crosses with said rake faces at said acute angle to define therebetween said cutting edges.