I've done my own handles but never a complete razor. With the availability of 3D printers you would think people would start playing with their own designs.
I agree. Gillette/Every-Ready/Schick/GEM/Merkur/et. al. did not hire multiple engineers because razor design was a piece of cake. I don't know what I don't know in razor design, but I am guessing that is a bunch of stuff about both design and produceability in the manufacturing environment. There are also possibly toxicity issues and other issues. Given the plethora of well designed and produced razors, both vintage and modern, I will just buy mine. It is probably cheaper in the end.
As long as you don't make your razor out of lead, gallium, etc, etc there are no toxicity issues if you know about metal alloys.
There would definitely be a cool factor in designing and making your own razor, but I don't really see a benefit other than that, you're not going to save money, and probably won't think of anything too revolutionary lol.
Unless you come out with a sweet toggle. Then you'll have people lining up to buy them and offset your design and manufacturing cost ;D
I'm really excited to see 3D printers slowly be made available to the masses. I suspect this with 3D laser we'll be able to produce many,many items including razors, bowls and such. Just as the automobile displaced the horse & buggy I predict that with 3D printer it'll be a tsunami that sweeps across the mfg landscape and very little will be the same. Although there will be certain items that will be worth buying in original form as their strength will be tough to beat copied.
You could probably ask Phil of Bullgoose to figure out the logistics since he and Lee Cantor of Lee's Razors are designing two new-design razors right now (the Cobra Classic-style one and an injector one). He made a video of a resin model of the CC-style one and said the the model would probably end up being more expensive than the production ones (which will be stainless steel).