John Roy of Dawson Knives: Magnacut steel is redefining survival tools

By kevinhughes // 2025-01-06

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Magnacut steel, developed in 2021 by metallurgist Larry Thomas, combines the sharpness of high-carbon steel, the corrosion resistance of stainless steel and exceptional flexibility, making it a groundbreaking alloy for knife-making and aerospace applications.
Magnacut excels in extreme conditions, resisting 30 days of saltwater exposure and maintaining durability in harsh environments, such as rural living or high humidity.
The smelter producing Magnacut and other powdered metals has issued a 90-day shutdown notice due to economic pressures, potentially making this innovative steel a rare commodity and threatening its future availability.
Dawson Knives, led by John Roy, uses a unique differential heat treatment combining ancient Japanese techniques with modern metallurgy, resulting in rust-resistant, durable blades with a razor-sharp edge.
Magnacut knives represent a fusion of functionality and craftsmanship, but their future is uncertain due to regulatory and economic challenges facing the American steel industry; Roy emphasizes the importance of preserving this "greatest American steel invention."

In the world of knife-making, a groundbreaking innovation is taking center stage – Magnacut steel. Developed in the United States, this revolutionary alloy combines the sharpness of high-carbon steel with the corrosion resistance of stainless steel, all while maintaining flexibility and durability. John Roy of Dawson Knives, a second-generation knife maker based in Arizona, shared the transformative potential of Magnacut steel in a recent interview on the "Health Ranger Report" with Mike Adams. Roy showcased its unparalleled performance in extreme conditions. From resisting 30 days of saltwater exposure to surviving the rigors of rural living, Magnacut is a game-changer. But with the steel industry facing potential shutdowns, this innovation might soon become a rare commodity. Could Magnacut be the last great American steel? Magnacut, a powder metal steel developed in 2021, is the brainchild of metallurgist Larry Thomas. Its unique chemical composition allows it to achieve what was once considered impossible: the sharpness of high-carbon steel, the corrosion resistance of stainless steel, and the flexibility needed to prevent shattering. "This new steel is very sought after in the aerospace industry," Roy explained to the Health Ranger. "It's a whole different take on how to put molecules and alloys together to form a steel that is super stainless without a lot of chromium, giving you a razor-sharp edge that's easy to sharpen in the field." The steel's versatility has made it a favorite among knife makers, but its production is under threat. Roy revealed that the smelter responsible for producing Magnacut and other powdered metals has issued a 90-day shutdown notice due to economic pressures. "If we lose this American-made steel, we lose the heart of America," Roy warned. "Steel drives everything here."

Dawson Knives combines ancient Japanese techniques with modern metallurgy

What sets Dawson Knives apart is not just the use of Magnacut but the proprietary heat-treating process developed by Roy and his team. Combining ancient Japanese techniques with modern metallurgy, they have created a differential heat treatment that ensures a stronger edge while maintaining flexibility. "We failed 20 times before we got it right. But through prayer and perseverance, we found a method that ties Old and New World technologies together," Roy admitted. This process results in blades that are not only durable but also highly resistant to oxidation. "These knives are very rust-resistant. Nothing is rust-proof, but these can handle extreme conditions, whether it’s left in a ranch vehicle or exposed to high humidity." The collaboration between Roy and Adams, co-designer of the knives, has yielded a line of survival tools that push the boundaries of functionality. The Outfitter and Outfitter Pro machetes, crafted from Magnacut, are designed for everything from clearing brush to food prep. (Related: Health Ranger Report: High-grade corrosion-resistant knives co-designed with Dawson Knives a popular choice among backpackers and preppers.) "This is a multi-purpose utility and survival tool," Adams said. "It's a once-in-a-lifetime purchase." The knives feature a unique hollow grind, achieved using a 14- to 16-inch wheel, which provides a razor-sharp edge while maintaining enough "meat" behind it for durability. "We’re not here to make axes," Roy explained. "We’re here to make knives that can be axes and knives." Despite its success, the future of Magnacut is uncertain. With the steel industry grappling with regulatory challenges and economic pressures, the availability of this revolutionary alloy may soon be limited. "If you see these steels, buy them," Roy urged. "You may not get another chance." The potential loss of Magnacut underscores a broader issue: the decline of American manufacturing. Adams lamented that America has already lost too much steel infrastructure, adding that "the regulators are weaponized against American businesses." For Roy, the creation of these knives is more than just a business – it's a legacy. While the knives and machetes crafted from Magnacut remain available, but their future is uncertain. As he put it: "This is one of the greatest American steel inventions. Let's hope it doesn't go by the wayside." Follow Gear.news for more news about knives and other survival tools. Watch the full interview between John Roy of Dawson Knives and the Health Ranger Mike Adams below. This video is from the Health Ranger Report channel on Brighteon.com.

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Dawson Knives combines ancient Japanese techniques with modern metallurgy

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