The process of making a Japanese sword is fascinating for many reasons. The swords are legendary for their strength and sharpness. The process of making the traditional steel for the sword is interesting both from the metallurgical standpoint and the historical standpoint. And then there is the art/beauty of the swords.

This video shows how a smith fashions a sword from a chunk of metal using only heat and a hammer (plus an occasional grinder):

How to forge a Katana:

Where did the Japanese get their steel hundreds of years ago? They used a very early, small-scale smelting process. The process is fascinating, as demonstrated here:

Japanese Sword: Tamahagane Smelting with Bladesmiths Walter Sorrells and Jesus Hernandez:

For more information on the smelting process (as well as the characteristics of Tamahagane steel), the following video is helpful:

For lots more information:
- How Iron and Steel Work
- How Sword Making Works
- DIY – make a knife

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