A method for manufacturing hand tools, such as wrenches. The method generally includes the steps of providing a flat stock, cutting the flat stock into the desired two-dimension blank using a laser, and three-dimensionally machining the laser-cut 2D blank into the desired three-dimensional workpiece. The tool may undergo a heating treatment process and a surface treatment process. In the context of a wrench, the blank may be laser cut with a laser beam oriented to cut generally perpendicularly to the plane of the flat stock. After laser cutting, the handle and interface region between the handle and jaw(s) are machined to provide the desired three-dimensional shape. For example, the three-dimensional shape may be selected to provide a comfortable grip even when applying a high level of force. The wrench jaw may have an optimized geometry calculated so that there is no excess material or “over-designed” regions of the jaw. The wrench jaw has internal corners with optimized radii.