Methods and devices are described for the design and manufacturing of a knife with a robust cutting edge profile for use in surgical procedures. The cutting edge profile may be defined by a combination of a cutting edge angle and a radius of the cutting edge tip. In some embodiments, the cutting edge profile may be defined by a combination of a web thickness profile and a radius of the cutting edge tip. Numerical ranges are identified for each of the various geometric parameters which may define a cutting edge that provides sufficient knife sharpness over many cutting repetitions. In some embodiments a medical device, which implements a knife with a cutting edge, for use in surgical procedures is described. Methods for forming a knife with a cutting edge including a cutting edge angle, a cutting edge tip radius, and/or a web thickness profile are described.