How the Best Knives and Blades Are Created

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How the Best Knives and Blades Are Created – Explaining the Forging Process of Katana in Detail

Truly, the Japanese blade, particularly known as Katana, is one of the most well-renowned swords in the history of Japan. Its single-edged curved design makes it a popular choice for samurai.

Besides its design, it is well-appreciated due to its excellent craftsmanship. A Japanese blade or Katana is made after a variety of processes. Among the different processes, the forging process only is divided into several steps.


The Forging Process of Katana:

FirstMaterial Selection

To begin with, the Katana forging process begins with the selection of material. Materials including “Tamahagane Steel” are primarily used in crafting Katana’s blade.

Next, the high-quality Tamahagane steel is extracted from the oroshigane refining process. It is important to know that the Tamahagane steel should have a carbon content of at least 1.0-1.2%.


SecondHeating of SteelHow the Best Knives and Blades Are Created

Secondly, once the steel is extracted, then it is heated to a temperature between 2192°-2732° F (1200-1500°C). After heating, the Tamahagane steel is hammered, pressed, and rolled into plates with an average thickness of ¼ inches.


ThirdMaking of Shingane and Kawagane

Third, the ¼ inch plate of Tamahagane steel is broken into pieces for the making of shingane and kawagane. Shingane is the softer part of Katana. It is made up of low-carbon steel. It is considered as the core of the blade.

On the other hand, Kawagane is harder. Even more, it is made up of high-carbon steel and is considered the outer layer of Katana. The material is selected according to density and color.



FourthJoining the Handle

Next, a steel plate with a composition exactly matched to Tamahagane steel is firmly joined or welded to the handle’s end. Selected portions of Tamahagane steel with an average weight of 4-5 pounds are stacked on the steel plate (3*5 inches).

After stacking, it is wrapped in rice paper followed by heating at 2372 degrees F (1300 degrees C). We can also use lint-free microfiber cloth, kimwipes, and silk cloth as alternatives to rice paper. But, if we are following the traditional forging process, then it is important to use rice paper.


FifthPreparation of Kitae

Fifth, when the tamahagane steel heated pieces are joined together through numerous strikes of the hammer, it results in a single bar of steel with appropriate carbon content. The metal bar is hammered continuously to extend the length of tamahagane steel for the preparation of the forging process or “Kitae.”


SixthFounding Forging or Shita-Gitae

Next, the process of dividing the bar of steel into 2 equal parts is called founding forging or shita-gitae. This is usually done by inserting a chisel into the metal (heated) until the bar of steel is cut into two equal pieces. 

Once two equal pieces of steel bar are achieved, then the bisected metal bar is folded back upon itself. A hammer is used to strike the folded bar to fuse the two divided halves. This is known as the folding process. This process is repeated numerous times and is important in removing the impurities from the tamahagane metal.


SeventhAppearances of Jitetsu and Jihada

Seventh, Jijetsu is defined as the appearance as well as the quality of the steel itself. It indicates the pattern and visible texture of the surface of the blade.

On the other hand, Jihada is the texture or surface grain of the tamahagane steel that becomes visible after polishing. The folding process of tamahagane metal greatly influences both jitetsu and jihada. These techniques can change depending on the forging style of the wordsmith. 



EighthFinish Forging or Age-Gitae

In the forging of Makotoswords Katana, 4 fragments of folded steel are piled over each other and joined together in a process called “Finish Forging” or “Age-Gitae.”


NinthTsukurikomi – How the Best Knives and Blades Are Created

Then, the forging process of Katana is then proceeded by joining the shingane and Kawagane together. This process is known as Tsukurikomi. During this process, the kawagane steel (particularly the fused part) is leveled into a plate. It is then bent into a U shape.

Also, this is important to form the hard jacket of the Katana blade. Lastly, the shingane steel fused bar is then adjusted according to the shape of the Kawagane jacket so it fits properly.

Then, once the setting is done, the shingane is inserted into the jacket of the kawagane. Once inserted, both metals are heated and joined together.  

Note: Carefully insert the shigane into the kawagane. If this process is not done properly, the ultimate blade will not be as expected.


FinallySword Blank or Sunobe

When the shingane and Kawagane are properly joined together, the smith then begins with heating and shaping the tamahagane metal into a Sword Blank or Sunobe. Even more, the sunobe must be exactly or in close resemblance to the finished shape of the Katana. And with that, the forging process of  Katana comes to an end. 

After forging, various processes, including annealing, shaping, hardening, tempering, polishing, and final sharpening, are performed, resulting in your own hand-made Katana.


The Takeaway – How the Best Knives and Blades Are Created

In closing, Katana is a unique sword that is appreciated for its unique traditional craftsmanship. Indeed, the swordsmith put great effort into crafting the Katana. It requires hard work as well as patience.

Only the forging process of Katana is further divided into ten steps. And, once forging is done, the other processes including annealing, shaping, hardening, etc are performed to get your hand-made Katana.

After reading, you may want to look into adding more of these knives to your home. Or, perhaps you would enjoy owning a well-crafted sword. Also, these products could make excellent gifts.



(Special Note – I was gifted a beautiful kitchen knife from Sakuto Knives in exchange for sharing this post.

Truly, the knife is absolutely beautiful, and I am looking forward to using it in the kitchen.)



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