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It took close to two months for the GGG design team to come up with the basic design of the Battle Hawk Tactical Tomahawk. Once that was accomplished the team had to select the material for the body. The team "short listed" four different types of steel. They were looking for a steel that was shock resistant and could withstand the stresses encountered in high impacts. It needed to be corrosion resistant yet wear well and be extremely resistant to chipping and breaking, especialy after being heat treated to a range of 56-58 rockwell. The design team did not want to take the risks associated with a handle made from poly carbonate whatever or wood, but instead wanted the head and handle to be one solid piece of steel that would not flex or be damaged when used to pentrate aircraft skin, helicopter skin, kevlar or 55 gallon drums. It is important to note that in the process of material selection, price was not to be considered a factor. The teams first responsibility was to select the "right" material for the specified use and overall design characteristics of the Battle Hawk. After careful review and testing, S7 tool steel was selected. S7 tool steel is a very expensive material but fits the teams criteria well. As a side note, we purchase the material in 36in X 70in X .400 sheets, and in quantities that reflect the economy of size, but it is still expensive.

The second major component, the scale material, was less complicated to select. The team knew that a G10 scale material was at the top of their list. It has low moisture absorption charecteristics, is extremely durable and is resistsnt to most chemicals and solvents. Standard G10 is a loosely woven fiberglass product that is impregnated with an epoxy resin. The team felt that to insure a very positive hand grip on the Battle Hawk, G10KG was a better choice than standard G10. The weave of the G10KG is much tighter and has a denser pattern than standard G10. It is a bit more durable, provides a better grip surface, and will withstand both dry and humid conditions. It is an excellent scale material. As you can see the Battle Hawk is made up of two basic components, S7 steel and G10KG scales. Alright, for those really counting there are four basic components if you add the Sherwin Williams powder coating and cap screws used to install the scales. But even with two major components and two minor ones, but not many realize it takes eight times that number of operations to manufacture one. That's right! There are thirty two distinct operations in the manufacture of this tactical tool, with all but three of them being completed at the GG&G facility in Tucson Arizona. From laser cutting the raw shape from the large sheets of S7 steel to the final sharpening and final inspection, the Battle Hawk goes through thirty two operations and is handled by at least six different skilled technicians along the way and that doesn't include the numerous operations necessary to hand form and assemble the Kydex sheath included with each Battle Hawk.