How to Make a Samurai Sword

Smelting steel
The traditional katana sword is fashioned only from the purest steel, which the Japanese call tamahagane (“jewel steel”). Over three days and three nights, smelters using ancient techniques shovel roughly 25 tons of iron-bearing river sand and charcoal into the mouth of a tatara, a rectangular clay furnace built specifically to produce a single batch of tamahagane. Composed of carbon, the charcoal is as much a key ingredient in steel as a source of fuel for the furnace. The tatara will reach temperatures of up to 2,500°F, reducing the iron ore to steel and yielding about two tons of tamahagane. The highest quality tamahagane can cost up to 50 times more than ordinary steel made using modern methods.

Dissolving carbon
While fired at high temperatures, the tamahagane is never allowed to reach a molten state. This is to ensure that just the right amount of carbon will dissolve into the steel, and that the percentage of carbon will vary throughout the tamahagane (between 0.5 and about 1.5 percent). Katana-makers use two types of tamahagane: high-carbon, which is very hard and allows for a razor-sharp edge, and low-carbon, which is very tough and allows for shock absorption. A sword composed simply of one kind of steel or the other would either dull too quickly or be too brittle. On the third night of smelting, when the tatara masters break open the clay furnace to expose the tamahagane, they use the degree of ease with which the pieces of newly made steel break apart to discern their carbon content.

Removing impurities
The best pieces of tamahagane are sent to a swordsmith, who heats, hammers, and folds the steel repeatedly in order to further combine the iron and carbon, and to draw out any remaining undissolved impurities, or “slag.” This step is as vital as it is tedious, because if other elements besides iron and carbon remain in the resulting sword, they will weaken it. Once the skilled smith has removed all of the slag, he can judge the carbon concentration of the tamahagane by the degree to which it yields to his constant pounding. One expert has likened eliminating slag from steel to squeezing liquid from a very hard sponge.

Forging the sword
After the smith hammers all slag from the tamahagane, he heats the hard, high-carbon steel and shapes it into a long, U-shaped channel. He then hammers the tough, low-carbon steel, which he has shaped so it will make a snug fit into the channel and forges the two metals together. Both types of tamahagane are now exactly where they need to be: the hard steel forms the sword’s outer shell and deadly blade, while the tough steel serves as the katana’s core. This perfect balance of properties is what made the katana the samurai’s most durable and prized weapon.

Coating the katana
While the katana’s body is now complete, the swordsmith’s work is far from over. Just prior to firing the sword a final time, he paints a thick, insulating mixture of clay and charcoal powder onto the blade’s upper sides and dull back edge, leaving the sword’s sharp front edge only lightly coated. This serves both to protect the blade and to give it its signature wavy design called the hamon, which later polishing will reveal. The swordsmith then places the katana back into the fire to be heated to just below 1,500°F; any hotter and the sword might crack during the next step.

Curving the blade
Next, the smith pulls the katana from the fire and plunges it into a trough of water in a rapid cool-down process called “quenching.” Because the sword’s back edge and inner core contain very little carbon, they can contract more freely than the high-carbon steel at the front edge of the blade. The difference in both the degree and speed of contraction between the two forms of tamahagane causes the sword to bend, creating the distinctive curve. This is a tricky stage, in which as many as one in three swords is lost.

Polishing the blade
The katana, fully forged, now goes to a skilled sword polisher, who may spend more than two weeks honing the sword’s razor-sharp edge. He meticulously rubs the blade with a series of grinding and polishing stones, some valued at more than $1,000 each and often passed down through families for generations. Sometimes called “water stones,” these tools are typically composed of hard silicate particles suspended in clay. As the clay slowly wears away during use, more silicate particles are revealed, guaranteeing excellent polishing quality throughout the life of the stone. Each consecutive set of polishing stones contains finer and finer silicate particles and removes less and less of the steel.

Adding final touches
In the final stage, metalworkers add a decorated guard of iron or other metals at the sword’s hilt. Next, carpenters fit the weapon with a lacquered wooden scabbard, which artisans then decorate with various adornments. Fashioned from gold or exotic leathers and stones, the katana’s handle is as much of a work of art as the blade itself. Finally, the katana is returned to the swordsmith, who examines the weapon one last time. It has taken 15 men nearly six months to create this single katana sword. Though fit for a samurai warrior, this sword will likely sell to art collectors for hundreds of thousands of dollars.

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• The Stuff of Metal
• Way of the Warrior
• Making a Masterpiece
• History of the Samurai

Japanese master craftsmen turned a pile of crude iron into the deadly Samurai sword.

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From a historical point of view, Samurai swords were one of the traditionally made Japanese Samurai swords that were used by Samurai of feudal Japan. Most of Samurai swords are characterized by a curved, slender and single edged blade. Samurai sword guard could either be circular or square in shape. It has a long grip that can allow the user to use both hands at the same time.

Samurai swords like the Katana were develop from the tachi, with a new big twist, the Katana was worn with the cutting edge up, allowing for a swift and easy draw of the sword and attacking in one single motion. This sword’s popularity came about because of the changing techniques in close combat warfare. The goal of using these Samurai swords is to allow the user to draw and strike the enemy in one fluid motion. The victory of the Samurai lies in his quickness in responding to a fight. The Samurai sword Katana was worn using a belt like sash called Obi. and was often paired with a Wakizashi. These pair is referred to as daisho. This privilege is given to the Samurai only. These swords represent his power and social standing. This gives him the honor to be known as a warrior of feudal Japan.

The Legend of Samurai Swords

Before the advent of those samurai swords, swords were imported from China. One of the famous swordsmith and his son forge a high quality Japanese blades. This replace the broken swords use by army that suffered irreparable damage during one of the wars. The next war turn into victory for the Japanese thanks to this sword. The Samurai sword is the Samurai soul. This deep attachment to his weapon results to a perfect blend of form and function. This is why using the finest and purest steel is essential. The process of producing a tamahagane like this takes time and need to be made step by step following the traditional sword making techniques of the master swordsmiths. The perfect balance of properties makes this sword a durable and highly prized weapon.

Samurai Swords Forging and Construction

Tamahagane is used to create a Samurai sword. This is a specialized Japanese steel. Not all Samurai swords are created from Tamahagane, however those are prized the most. Differential hardening and quenching is used to produce a gentle curve. Wet clay slurry is use to coat the blade before it is quenched. When subjecting these blades in such high temperature this produces a very hard form of steel. After the forging process, the blade is sent to be polished. Fine grains of polishing stones are used to make these blades shine like a mirror. The final process calls for drilling a hole in the non-edge part of the blade or tang. Bamboo pieces are tied using a cord. Because of the processes that these Samurai swords have gone through these are well known for being exceptionally sharp and tough.

Sword Creation Process

• Smelting the steel
• Dissolving the carbon
• Removal of impurities
• Forging the sword
• Coating
• Curving the blade
• Polishing
• Additional final touches

Samurai Today

Samurai swords remains appealing to a wide range of people even those that are of different culture. Some martial arts promote the use of these swords by teaching different kinds of techniques. However, the ownership of a sword like this follows strict regulation. In movies or in stories, these swords inspires legends and invincible warriors of long ago. Myths have been form inspired by this sword. Some of them are true and some are not.

• Swords like these can cut through silk when it is drop on the blade. The truth is that Japanese swords can slice objects when the blade is pulled across the target. This means no slicing will take place when the cloth is drop on the blade
• This can chop other swords into two. The fact is that any sword can be hit by a hard target in the wrong angle and can break however, chopping will not be able to cut the sword in half
• Trapping a blade using two hands is a skill that can be mastered. Movies are responsible for this myth. The truth is if anyone attempts to do this they will likely get serious cut.
• Samurais are not allowed to place the sword in its scabbard without drawing blood. Fact is that this is not true and it’s just a myth
• Thousands of sword like these were thrown into the ocean when Japan surrendered to America. Fact is that only some were cast into the sea aboard ships just like any other forms of weapon onboard. This was done to prevent the Japanese soldiers from causing harm with the use of weapons like these

Proper Maintenance

If these Samurai swords are not properly stored this can damage the swords beyond repair. It is therefore essential to store the blade horizontally in its sheath. The curve must be place down with the edge facing up. Oiling, powdering and polishing is needed to keep the blade from falling into rust. The use of choji oil is advisable since this oil has the right ingredients to protect the blade from rust. If the sword is stored for a long period of time it is essential to inspect it frequently and air it from time to time to prevent mold and rust from damaging it. Samurai swords have remain to be perfect examples of beauty and skillful engineering. Not all kinds of swords can have the power to pierce and slash. This makes these swords highly versatile weapon in battle and out of it.

Using accidental chemistry and sheer brute force, swordsmiths in 12th century Japan took crude pig iron and turned it into a deadly weapon—the Samurai sword.

In the 12th century, master craftsmen in Japan transformed pig iron—a weak metal riddled with impurities—into a material strong enough to help shape our world.

Over centuries, Iron forging was turned from a skill into an art form.

Using technology that wouldn’t reach Europe for hundreds of years, Japanese swordsmiths created the samurai swords, famous for their unparalleled strength.

This deadly weapon started life as an impure lump of crude pig iron.

So how do you transform it into the amazing metal of the samurai?

Rick Vinci, a metals expert from Lehigh University reveals that the secret is simply brute force…

They would heat it and hammer it, and after they had done so they would fold it over upon itself and heat it and hammer it again, and they would do this many, many times. And every time they would go through this hammering process they would drive out many of the impurities.

With every blow the impurities are smashed away. It takes hundreds of blows but every time it is hit this metal becomes purer and purer.

And unbeknownst to them they would also be altering the carbon content.

Carbon is the most important impurity in iron.

Too much and the iron will be brittle, not enough and it will be soft.

But by smashing out just enough carbon the swordsmiths were left with a metal with extraordinary strength and unmatched flexibility.

The end product was really good material, they could make swords out of it that would hold a sharp edge, that would survive use on the battlefield without shattering.

What the swordsmiths had created was a new kind of metal…

A new alloy—that to this day is the strongest, most useful alloy we’ve ever discovered—steel.

Of all the iconic national symbols, none is more representative of Japan’s time-forged traditions than the samurai sword.

Said to possess a warrior’s very soul, the samurai sword has been marvelled at for its flawless beauty and unrivalled engineering for over a millennium. Centuries ahead of its time, Japanese sword making was passed down from master to pupil for generations and revered as part art, part religious ritual. So how exactly were they made?

How samurai swords were made

The great swordsmiths of Japan were more alchemists than blacksmiths. Requiring a deeply intimate knowledge of chemical metallurgy, the traditional sword making process was anything but straightforward. Dozens of craftsmen would work around the clock for months on end, sometimes longer, to produce a single blade.

Step 1: Making the steel

The starting steel, tamahagane, is produced by smelting iron sand (sand containing iron ore) with charcoal in a large clay furnace known as a tatara. Once the correct temperature is reached, it’s up to the tatara masters to carefully monitor the tatara, feeding in iron sand and charcoal as needed. This step is crucial, and requires the team to be on hand for 72 hours without pause.

Step 2: Sorting the steel

After the three day smelting process is complete, the tatara masters break open the clay furnace to extract the tamahagane. From this, they break apart and separate the steel mass according to carbon content. When expertly combined, high-carbon steel and low-carbon steel will imbue the blade with a razor-sharp edge and toughness, respectively. A sword composed of just one type of steel would result in a blade that would be too brittle or dull easily.

Step 3: Purifying the steel

The best pieces of tamahagane are sent to a swordsmith, who heats, hammers, and folds the steels repeatedly—up to 16 times— in order to further combine the iron and carbon, and to draw out any remaining impurities, or ‘slag’.

Step 4: Forging the blade

After the smith hammers all impurities from the different steels, high-carbon steel is heated and shaped into a long piece with a U-shaped channel. The low-carbon steel is also heated and hammered into a strip that fits snuggly into the channel. The two metals are then forged together. Both types of tamahagane are now exactly where they need to be; the hard steel forms the sword’s outer shell to provide the sharp edge, while the tough, low-carbon steel serves as the durable core.

Step 5: Coating the blade

With the blade steel now ‘assembled’, it requires one last firing. A thick mixture of clay and charcoal powder is applied to the blade’s upper sides and dull back edge, leaving the sword’s primary edge only lightly coated. This serves both to protect the blade and to give it its signature wavy design called the hamon, which is revealed later during the final polishing. The blade is then fired to just below 815°C (1500°F). Any hotter and the blade is at risk of cracking.

Step 6 :Curving the blade

The blade is pulled from the fire and plunged or ‘quenched’ into water. The difference in the degree and speed of contraction between the two forms of steel in the blade causes the sword to bend. This process gives the sword its signature curve.

Step 7: Polishing the blade

Now fully forged, the blade is passed to the sword polisher. The blade is meticulously polished with a series of grinding and polishing stones to hone the sword’s razor edge. This polishing step can take several weeks, sometimes months.

Step 8: Mounting the blade

Metalworkers mount the blade with its decorative guard (at the sword’s hilt). Carpenters then fit the blade with a lacquered wooden scabbard, which artisans then intricately decorated. The handle is then fashioned with gold, leather and/or stone. These final steps produce finishing touches that are as much a work of art as the blade itself.

Step 9: The final inspection

The finished sword is returned to the swordsmith for its final inspection. If acceptable, the sword is ready to be presented to its new master.

From the battlefront to the kitchen

During the 1300s, a time of war and conflict for Japan, skilled sword masters were in high demand. However, when the shogunate lost its power and the Meiji Restoration period began, Japan sought to modernise, and the samurai class lost their privileges and position within society. With the demand for swords reduced, craftsmen and manufacturers turned their efforts to knife making instead.

Today, the art of Japanese cutlery is a direct descendant of Japanese sword making, with many of the same techniques and designs still being used. With authentic, traditional samurai swords fetching astronomical prices (if you can even find one for purchase), owning a quality, Japanese piece of cutlery is the next best thing.

Some of the best places to purchase Japanese knives and cutlery in Japan are:

Kappabashi street (Tokyo) — a street lined with kitchenware shops
Sakai City, Osaka — approximately 90% of professional chefs in Japan source their knives from Sakai
Seki City, Gifu — a city famous for world famous blades. Don’t miss the Seki Swordsmith Museum.
Miki City, Hyogo — one of Japan’s largest producers of hardware tools and knives

Experience a slice of history

Want to see how traditional tamahagane is made? The Bizen Osafune Sword Museum is one of a limited number of sword museums in Japan and features an impressive collection of Japanese swords. Visitors can also attend a sword maintenance seminar and talk to the craftspeople responsible for the various components of the sword.
In the adjacent workshop, visitors can see the skill of Japanese sword artisans, including the process where tamahagane, the steel traditionally used to make samurai swords, is produced (limited dates and times).

There is also a Japanese Sword Museum in Tokyo dedicated to the art of Japanese sword making, run by the Society for the Preservation of Japanese Art Swords. The museum is a short walk from Ryogoku Station on the JR Sobu Line or Toei Oedo Line.

You can also experience a bit of samurai culture closer to home with one of the JNTO samurai AR effects on Facebook and Instagram.

The katana (also known as the samurai sword) originated in Japan’s Muromachi period (1392–1573). These curved blades are known worldwide for their elegance and craftsmanship. But if you can’t afford your own antique model you can create your own reproduction using junk you’ve probably already got in your garage.

5 sheets of cardboard, 4 inches by 30
Wood Glue
A paintbrush
A saw to cut out the Katana shape.
Sandpaper, medium grit.
Paints.
Aluminum foil.
A roll of clear packing tape.
Black, blue and red electrical tape.
White glue.

1. Cut out six sheets of cardboard in 4 x 30 inch pieces, three pieces where the grain of the cardboard runs one way, three pieces where it runs the other way.

2. Take two pieces with opposing grains and apply wood glue to both, using a brush to spread it out. Repeat this process until you have the six sheets glued together.

3. Pile books or other heavy objects on top to weight the cardboard down and smooth it out. Leave it overnight.

4. The next day, draw the shape of the katana on the cardboard. Use this as a pattern when you cut out the katana.

5. Apply a layer of carpenter’s glue on the edges of the cardboard katana, covering the corrugations. Now again let the project sit overnight.

6. Now it’s finally time to decorate the katana. You can either use paint, or you can decorate it with aluminum foil and tape, using the clear packing tape to protect the foil.

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The meticulousness with which the Japanese make objects touches almost every aspect of ​​their daily lives – from books and precious papers to tea sets, the elegance and dedication would seem to endow such objects with value that others simply don’t possess. It’s as if the care with which they’re made gives them a soul all their own. There’s perhaps no greater display of this technical skill than in the production of the samurai sword, the Katana. It’s an object which stands out not only as the weapon of the legendary sect of warriors but as a further attempt – one that’s essentially Japanese – at attaining perfection.
The process of creating the sword, a ritual in and of itself, begins with a Shinto blessing. Shinto is the indigenous religion of Japan, based in the worship of nature spirits. This is followed by the careful preparation and selection of the steel and iron to be used in the process, and its careful covering in the ash and mud that prevents oxidation.

Forging, the striking of the red hot metal with a special hammer, brings the metal to the desired shape. This includes a process of repeated folding which combines just the right amount of hard steel with soft steel. Without the folding process, the sword would be very hard, but never sharp and easily broken. The mixing of the metals in the sword is a process that appears more like an act of alchemy: achieving that perfect combination of hardness and softness.

When the metal has been tempered, and the blade of the sword is ready, it’s engraved with the signature of the one who made it, as artists do with their most precious work. Then the metal is polished to give it shine and an imposing edge. Finally, the handle of the sword and a sheath, both of wood, are manufactured in processes no less sophisticated nor impressive.

In Japan, about 30 master craftsmen dedicate themselves exclusively to the making of these meticulous treasures. The process of making the Katana is intended to achieve perfection, and each projects the personality of the one who made it. Thus, all Samurai swords are different from one another, like people. The process of making the Katana not only hypnotizes those who witness it, it also speaks to us of the sophistication evident in this method of creating objects and in living life.

The process is explained in detail, and with more information on the culture of the Katana, in the following extraordinary documentary.

*Image: Public Domain

The meticulousness with which the Japanese make objects touches almost every aspect of ​​their daily lives – from books and precious papers to tea sets, the elegance and dedication would seem to endow such objects with value that others simply don’t possess. It’s as if the care with which they’re made gives them a soul all their own. There’s perhaps no greater display of this technical skill than in the production of the samurai sword, the Katana. It’s an object which stands out not only as the weapon of the legendary sect of warriors but as a further attempt – one that’s essentially Japanese – at attaining perfection.
The process of creating the sword, a ritual in and of itself, begins with a Shinto blessing. Shinto is the indigenous religion of Japan, based in the worship of nature spirits. This is followed by the careful preparation and selection of the steel and iron to be used in the process, and its careful covering in the ash and mud that prevents oxidation.

Forging, the striking of the red hot metal with a special hammer, brings the metal to the desired shape. This includes a process of repeated folding which combines just the right amount of hard steel with soft steel. Without the folding process, the sword would be very hard, but never sharp and easily broken. The mixing of the metals in the sword is a process that appears more like an act of alchemy: achieving that perfect combination of hardness and softness.

When the metal has been tempered, and the blade of the sword is ready, it’s engraved with the signature of the one who made it, as artists do with their most precious work. Then the metal is polished to give it shine and an imposing edge. Finally, the handle of the sword and a sheath, both of wood, are manufactured in processes no less sophisticated nor impressive.

In Japan, about 30 master craftsmen dedicate themselves exclusively to the making of these meticulous treasures. The process of making the Katana is intended to achieve perfection, and each projects the personality of the one who made it. Thus, all Samurai swords are different from one another, like people. The process of making the Katana not only hypnotizes those who witness it, it also speaks to us of the sophistication evident in this method of creating objects and in living life.

The process is explained in detail, and with more information on the culture of the Katana, in the following extraordinary documentary.

*Image: Public Domain

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The Handmade Swords Expert

At the Handmade Swords Expert, you can find high quality handmade samurai swords. We are different from other sellers or wholesalers who are just in the middle making a commission. You cannot guarantee the quality from these suppliers. All the swords on sale through us are handmade by our experienced swordsmith. This is not a simple and cheap copy hand forged.

Each sword goes through a complex process of quenching and forging to ensure the hardness of the blade edge and the toughness of the blade. There are many styles and types to choose from on the website, including the mainstream types of Katana and wakizashi and the ninja sword.

You can not only use the samurai sword for exercise and to also present it in your home as a very beautiful and valuable work of art. Everyone who sees your sword will be amazed by its beauty and great. Please be assured that we have the very best shipping capabilities and insurance. We promise you a quick and safe delivery of your order.

Hi, Thanks for visiting my website. My name is Will and if you have questions
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You can make a very nice, and very durable Katana out of cardboard. You just have to know some basic techniques and understand the properties of cardboard. In this tutorial I take you through all the steps necessary and explain the process fully. Note that I also have a youtube video tutorial that shows how I made this cardboard katana

The completed Katana next to a real one.

We mimic the Japanese Sword Makers when making this Katana in a couple of ways. First, the most important thing about a katana is that it uses two different types of steel and it is the combination of these two types of steel that gives the katana its remarkable strength yet flexibility. We do the same by using two different orientations of cardboard. Second, it takes time to make a real Katana and it will take us three days to make this cardboard sword! Yup, if you want to do it right you are going to have to take three days to do it. Now this doesn’t mean three days of straight work. It’s only one or two hours of work but you have to let the glue dry overnight at two different stages. That’s why it takes three days.

Before we start making this katana lets take a look at some cardboard. It is an important part of the process and you need to understand it.

Corrugated cardboard, which is what most boxes are made out are composed of two sheets of brown paper with a wavy layer of paper inside. It forms a kind of a sandwich. Now these corrugations, as you can see in the picture at left all run in one direction. When choosing your cardboard for your Katana make sure you note the direction of the corrugations.

You are probably going to need two large boxes for this. One box with the corrugations going one way and one with the corrugations going the other way.

So, to make this Katana, and to make it strong you are going to need five pieces of cardboard. Cut them four inches wide and thirty inches long. But notice the picture. Three of the pieces have the corrugations running the long way and two of them have the corrugations running the short way. This is very important and it is what will make the Katana very strong.

Materials Needed for this project

• 5 sheets of cardboard as shown above (4 inches by 30 inches)
• A Bottle of Wood Glue
• A Paintbrush to brush on the glue and spread it evenly (important)
• A saw to cut out the Katana Shape, A band saw is perfect, A jigsaw works good, You can also use a coping saw or if you have to you can use a utility knife. Be careful when cutting, wear safety glasses and safety gloves if recommended.
• Sandpaper, a couple of sheets of medium grit (optional)

Suggested Materials to Decorate and finish the Katana

• Paints – You can simply paint your Katana any way you want and it will be done. But to make it look better I have some recommended methods I will show you.
• Aluminum foil
• A roll of clear packing tape
• Black electrical tape
• Blue Electrical tape
• Red Electrical tape
• Glue stick or white glue

Let’s Continue with the Tutorial and Make this Cardboard Katana

2 Natural Bokens Wood Practice Swords, Wooden Daitos Training Katana These 40 inch natural traditional daito are ideal practice swords to safely practice your sword skills while protecting your self and partners. Constructed from hardwood and includes two piece handguard. Please note that these practice items can still cause serious injury or death if not used properly. Two piece hand guards may vary in color.