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The Forge PDF Print E-mail

Justin grinding on a Warlord sword.
Justin grinding on a Warlord sword.
Machinest Martin
Martin the machinist says the best thing about his job is making knives.

 

The forge is the focus of the forging, hardening and tempering process. Here the smith's tools are assembled – charcoal and steel, anvils and hammers, as well as quenching vats, furnaces and kilns. Tradition plays an important role in crafting a blade, but today the sword smith also works with modern tools – milling machines, sanders, grinders and presses.

All of our Avatar, Angel Sword, Bumon and Bright Knight blades are created entirely at our forge in Driftwood, Texas. Only our Buccaneer line is not crafted start-to-finish in Driftwood. Buccaneers are an affordable alternative that start with quality knife or katana blades which we then cryogenically process for increased toughness and adorn with hand-crafted handles.

Each future blade arrives at the forge as a simple bar of steel, usually 36 inches long. Some steel is ground and hammered into shape by traditional means – hammer, anvil, fire and sweat – but many of our blades begin on a CNC milling machine, where a computer shapes the steel into a close approximation of its final form.

Daniel Waston Open House forge demonstration 2007
Daniel Waston Open House forge demonstration 2007

From there, the steel undergoes a tempering process where it is heated and quenched to give it the hardness and toughness required in a combat weapon. Angel Sword recently added a cryogenic processing unit to our forge. After tempering the steel, we use our patented Therma-Cycle™ processing to enhance our steel at the molecular level, improving uniformity and relieving stress in the steel's crystalline matrix. This combined process is the reason Angel Sword makes the toughest, high-hardness blades on the planet.

After Therma-Cycle processing, the blades are hand ground to their final shape and sharpened. Then they are fitted with the appropriate furniture – handles, guards, pommels, etc. – with an eye toward both functionality and artistry. Finally, Daniel and the smiths examine the result with a highly critical eye. Only after passing this rigorous inspection is a blade allowed to leave the forge.

Shaping steel for a pummel work in progress.
Shaping steel for a pummel work in progress.
Its slowly coming into shape.
Its slowly coming into shape what could it be?

As you can see alot of work goes on at the forge.  Here you will find more images of work in progress and some of the crew at work.

Knife blades ready for heat treat.
Knife blades ready for heat treat.
Lots of blades just out of the Thermal Cycle tank.
Lots of blades just out of the Thermal Cycle tank.

New sword waiting for a handle
New sword waiting for a handle
Cant wait to see this one finished
Cant wait to see this one finished

 

 

 

 

 

 
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