One day, browsing a drugstore magazine rack, he discovered Knives Illustrated. That chance encounter not only reconnected him with his old passion but also led him to Stan Fujisaka, a respected custom maker in Hawaii. Fujisaka became both mentor and friend, guiding Onion through the essentials of knifemaking. He taught him how to grind blades, heat treat steel, and assemble knives with precision, stressing the importance of geometry, metallurgy, and patient craftsmanship.

Fujisaka’s lessons went beyond technique. He impressed on Onion that knifemaking was a union of art and engineering, one that demanded creativity as well as discipline. He encouraged experimentation, urging Ken to push past convention and develop his own style. This period of study and exploration would shape Onion’s approach to design, laying the foundation for the innovations that would eventually transform the knife industry.

Ken and Noel Onion with master knifemaker Stan Fujisaka

Ken first conceived the SpeedSafe mechanism while milling a cam for a friend’s motorcycle. He realized that applying a cam lever to a knife’s pivot could allow the user to start the blade’s movement manually. A torsion bar would then take over to complete the opening smoothly and safely. This produced a knife that could be opened with one hand without relying on gravity or wrist flicks, while also avoiding the legal restrictions on automatic knives.

Ken reinforced the idea by studying the laws surrounding knife mechanisms. Unlike automatics, which use a spring activated by a button or switch, SpeedSafe requires direct pressure on the blade or thumb stud. That distinction classified it as a manual mechanism under the law, ensuring the innovation was both practical and compliant.

- The SpeedSafe mechanism (pictured above) was inspired by motorcycle cams

After perfecting the SpeedSafe design, Ken Onion still faced the challenge of finding a company willing to take a risk on his unconventional mechanism. Most manufacturers hesitated, worried about legal issues or uncertain customer response. Everything changed in 1996, when Doug Flagg of Kershaw traveled to Hawaii after hearing about Ken’s invention at the SHOT Show. Convinced of its potential, Flagg brought Onion into the Kershaw fold, beginning a collaboration that would redefine modern folding knives.

In 1998, the partnership debuted the Kershaw Random Task, the first production knife to feature SpeedSafe. It became an immediate success and earned the Blade Magazine American-Made Knife of the Year Award, a remarkable first for both the design and the partnership. The momentum continued the very next year, when the Kershaw Blackout won Best Buy of the Year, proving that Onion’s knives could combine innovation with affordability.

In 2001, the Black Chive earned another American-Made Knife of the Year Award, while in 2002 the iconic Leek captured Overall Knife of the Year. Sleek, slim, and endlessly adaptable, the Leek remains one of Kershaw’s most popular knives to this day. Onion’s reputation as a designer who could blend ergonomics, aesthetics, and mechanical genius was firmly established.

The peak of the partnership came in 2005, when Ken and Kershaw claimed three separate Blade Show honors. The futuristic Offset won Overall Knife of the Year, the Shun Classic 8" Chef’s Knife took Kitchen Knife of the Year, and the Spyderco-Kershaw Spyker collaboration was named Collaboration of the Year. No other year demonstrated more clearly Ken Onion’s versatility, spanning tactical folders, kitchen cutlery, and cross-brand innovation.

Through knives like the Blur, Scallion, Chive, Shallot, and Offset, Ken Onion and Kershaw shaped an era of production knives that emphasized usability, flair, and advanced engineering. Their work not only produced some of the best-selling folders in the world but also cemented Kershaw’s reputation as a leader in assisted-opening technology.

- In 1996, Doug Flagg of Kershaw flew to Hawaii to view the SpeedSafe mechanism

- In 1998, SpeedSafe debuted in the Kershaw Random Task (pictured above) and was awarded as the American-Made Knife of the Year

After more than a decade of groundbreaking success with Kershaw, Ken Onion began a new chapter in 2008 when he partnered with Columbia River Knife & Tool (CRKT). This collaboration gave him the freedom to pursue fresh ideas and explore new mechanical concepts that went beyond assisted opening.

His very first major success with CRKT came in 2012, when the Foresight won Imported Knife of the Year at the Blade Show. With its bold curves and ergonomic grip, it demonstrated Onion’s ability to adapt his design philosophy to a new production partner while still delivering a knife that stood out in a crowded market.

In 2014, Onion and CRKT captured the Blade Show’s highest honor when the Hi Jinx was awarded Overall Knife of the Year. The knife combined striking aesthetics with premium steel and construction, showing that CRKT and Onion could compete at the very top tier of production knives.

Ken’s next great leap with CRKT was the introduction of Field Strip Technology in 2016 with the Homefront. This revolutionary design allowed users to disassemble their knives without tools for easy cleaning and maintenance, a solution to a long-standing challenge faced by knife owners. That same year, the Homefront earned the Blade Show award for Most Innovative Imported Design, a recognition that underscored Onion’s ongoing commitment to problem-solving through engineering.

- In 2008, Ken Onion partnered with CRKT

- In 2012, the CRKT Foresight (pictured above) was awarded Import Knife of the Year

The result was the Ken Onion Edition Knife & Tool Sharpener, released in 2013. Unlike traditional systems, it featured adjustable angles, variable speed control, and replaceable abrasive belts, allowing it to handle everything from delicate pocket knives to rugged outdoor tools. Ken was deeply involved in its development, working closely with the Work Sharp team both at his workshop and at their headquarters in Ashland, Oregon, to ensure that the device met his exacting standards. The sharpener was a resounding success, praised for its precision, versatility, and user-friendly design, and it quickly became one of the most popular powered sharpening systems on the market.

The collaboration did not end there. Building on the success of the original, Work Sharp and Onion introduced the Ken Onion Edition Knife & Tool Sharpener Mk. 2, an updated version that refined the formula with improved ergonomics, better angle guides, and expanded functionality. For enthusiasts seeking even more control, the partnership later unveiled the Ken Onion Edition Elite Mk. 2, which added a Blade Grinding Attachment and expanded belt options for advanced sharpening and edge shaping. These upgrades reflected Onion’s continuous push for refinement, offering knife owners not just maintenance but a full sharpening system that could evolve alongside their needs.

- After meeting Kyle Crawford of Work Sharp, Ken Onion partnered with them in 2012

- In 2013, Work Sharp released the Ken Onion Edition Knife & Tool Sharpener (pictured above)