Forged Step by Step: Inside the Blacksmith’s Workflow

Walk into a blacksmith’s shop, and you’ll likely see glowing steel, flying sparks, and a hammer ringing off the anvil. It’s loud. It’s hot. And it might look like chaos from the outside.

But behind the smoke and fire is a deliberate process—a sequence of steps that transforms raw steel into something purposeful, beautiful, and built to last.

Whether it’s a kitchen knife, a fireplace tool, or a decorative hook, every forged item tells a story. Here’s a look behind the curtain at what really happens between that first chunk of steel and the final piece in your hands.

Step 1: The Idea or Design

Every project starts with a vision.

It could be a sketch on paper, a mental blueprint, or a customer’s request. At this stage, I’m thinking about form and function—how the piece will be used, what size it should be, what kind of balance it needs.

For blades, it’s edge geometry and ergonomics. For home goods, it’s strength, mounting points, and aesthetics. Even a simple wall hook needs to be thoughtfully designed to do its job right.

Step 2: Choosing the Right Steel

Not all steel is created equal. For blades, I typically reach for high-carbon steel like 1084 or 5160—it holds an edge well and responds predictably to heat treating. For home decor or tools that won’t take an edge, mild steel (like A36) is often perfect.

Choosing the right steel isn’t just about performance—it also determines how the piece will move under the hammer, how it finishes, and how long it’ll last.

Step 3: Forging the Shape

Now the fun (and heat) begins.

The steel is heated in the forge until it glows bright orange—around 1800°F (980°C). That’s when it becomes soft enough to shape with a hammer. Using the anvil, various tools, and controlled strikes, I draw out, taper, curve, or punch the steel into the rough shape I want.

This is where the character of the piece is born. A twist in the handle, a textured spine, a decorative curl—these details happen right here, under the hammer.

Step 4: Heat Treatment

For functional tools and blades, heat treatment is where the real magic happens. After forging, the steel is normalized (relieved of stress) and then hardened—heated to a specific temperature and quenched in oil or water.

After hardening, it’s too brittle to use safely, so we temper it—usually in an oven—bringing it to a lower temperature to make it tough but not fragile. It’s a delicate dance of science and experience, and one of the most critical stages in the whole process.

Step 5: Grinding & Finishing

Once the steel is shaped and hardened, it’s time to refine it.

I move to the grinder to clean up rough edges, smooth out surfaces, and bring out the final form. If it’s a blade, this is where it gets sharp. If it’s a decorative item, this is when texture, patina, or polish is added.

I may add a brushed or blued finish, engrave a maker’s mark, or do final sanding to bring out a mirror shine or rustic matte. This step is where it all comes together.

Step 6: Handle, Mounting, or Assembly

If the piece has a handle—like a knife or tool—this is when it gets attached. I might use wood, antler, leather, or micarta, depending on the style and purpose.

For hooks, brackets, or décor, this is where mounting holes are drilled, mounting plates are added, or final adjustments are made for balance and fit.

Final Thoughts: More Than Just Metal

A finished piece might look simple—but behind it is hours (sometimes days) of thought, heat, muscle, precision, and patience.

That’s what makes hand-forged work special. It’s not just the steel—it’s the story in the steel.

So the next time you hold a forged knife or hang your coat on a hand-forged hook, you’ll know what really went into making it: vision, heat, skill, and soul.

Want to See the Process?

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If you would like to discuss a project, please do not hesitate to contact us.