I know the Ti is over kill but its what we have (oddly that, we never normally have anything!)

Copying the standard wood blades seemed the simplest option cos thats what its designed for only we would not have to worry about any small teeth flying off as we would with the commercial blades.

How about 2 or 3mm Aluminium rather than the Ti, would people prefer that? Though the alu would be much more likely to fail in battle in comparison to the Ti which could mean dangerous shrapnel...