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by UPKnife

UPK-D1 Pocket Sai 440A-SS BrightMetal (Thrower)

$199.95 $225.00

Designed from the ground up as an implementation of the Okinawan Sai, a defensive melee weapon that would be practical to carry and sheath itself.  The Handle slides to eclipse the blade's  edges and point, and makes an integrated sheath.  It's one-button locking mechanism is designed to engage at either open or closed position, and must me pressed to unlock it from either end.

 The UPK-D1 Pocket Sai is made in 100% HARDENED STAINLESS STEEL


Thrower - optimized material for throwing, this implementation was done in 440A, a high carbon martensitic stainless with a lower carbon content then its 440B and 440C relatives, this makes a tougher resilient stainless in exchange for reduced hardness. Heat Treated to HRC 37-40 these are still harder then most the objects around you, but will take extreme abuse and offer a point of bending where harder alloys will break, making this ideal of throwing practice and learning when the worst abuse takes place.

BrightMetal Finish - the raw milled heat treated stainless blade and handle are tumbled and then further polished before being micro ball peened, a process used in aerospace fabrication to reduce fatigue cracking and crack propagation in critical components.  This process requires a spherical media that is ultra hard and produces a  resilient micro orange peel effect.  This surface performs further to withstands scratches.

Traditional - The original Okinawan Sai is a defensive melee weapon optimized for non-lethal techniques used by Okinawan police to control and subdue, noting that the saki(point) or yoku(prongs) offer pointed tips that would be used when a more lethal need arose.  I chose to shape the monouchi(main blade) of the Pocket Sai with beveled edges that draw to a point at its end giving it a more ominous look and a more effective tip for its compact size. The bevels enhance a more focused contact pressure on soft targets and provide improved piercing with the saki.  In respect to the traditional Sai, the Pocket Sai is pointed without live edges, this provides better resilience to weapon on weapon impact in melee control techniques.  

Billet Milledfabrication process, from SOLID bar/plate material.  The Blade and handle are milled from a solid piece of Martensitic Stainless Steel, this is the strongest way my designs could be made.



  • Blade Milled from 440A Stainless Steel
    • Heat Treated to 37-40 HRC
  • Handle made in 440A Stainless Steel 
    • Heat Treated to 37-40 HRC
  • Custom Hardware(Button and screws) made in 450 Stainless steel
    • Heat Treated by Age Hardening to the H900 condition HRC 45
  • 301 Stainless Steel Springs
    • Cold work Hardened to a Spring Temper


  • Extended length: 11.7 inches (297 mm)
  • Collapsed length: 7.3 inches (186 mm)
  • Weight: 0.5 lb (8 oz.)

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