Endodontic instruments having a desired cutting edge are formed, at least in part, using a cold forming process. The method of forming the endodontic instrument includes providing a blank metal thread or wire and at least one die that has a negative impression of a cutting edge. The die is pressed against the blank with sufficient force in order for the die to form an at least partially formed cutting edge in the blank. Any desired shape can be formed into the blank by selecting a die with the proper corresponding negative impression. Cold forming techniques suitable for forming endodontic instruments include roll forming, flat rolling, radial forming, cold drawing, and similar techniques. The files can be sharpened or otherwise modified before or after cold-forming using techniques such as cutting, grinding, and chemical milling.