This thread has been moved to the Must Read subforum. Congrats (and thanks) to Jaden for making such a valuable contribution!
These are good considerations toward your goal to produce Perfect Handle drivers. Manufacturing wise, the challenge is forging round stock into a flat ear for attaching handle scales.
A variety of economical tool steels fit this, or case-hardening a good grade of mild steel at the tip. Temper either carefully to get away from brittle to tough characteristics.
The bits can be improved from wedge shaped to parallel though, as gunsmiths and cabinet makers use. Commercially, they are ground, but a sharp endmill will lay toolmarks in an advantageous direction.
I'd definitely retain the hex portion, larger in proportion to bit width so a ratchet type combination wrench or bypass socket fits, instead of an adjustable.
...we'll learn more by wandering than searching...
Great post and learned a lot too. Those screw drivers are beautiful! Thanks for all the info on them and the wood tips! Always loved Cherry wood, but had no idea it wouldn't make your hand sweat!!...Very Cool, Thanks! ~PJ
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