Information on Our Edged Weapons

Information on Our Edged Weapons

We do not sharpen the edged weapons in our collection that are suitable for test cutting before we ship them. However, their blades are designed to be sharpened by professionals or at home with the proper tools and techniques. Our stage combat swords, on the other hand, have the dull back edges that are required for stage combat.

Please note that all weights and measurements listed for our edged weapons, armor & equipment and helmets are approximate values. Because they are individually handcrafted, an individual product may deviate slightly. All dimensions are listed in centimeters or millimeters (1 inch = 2.54 cm).

Edged weapons and replica armor from Supreme Replicas – How our supreme quality steel products are created

Whether sword, armor, axe or helmet – all of the replicas at Supreme Replicas are made of quality steel handcrafted with care in a multi-step production process. The first step of our steel product development involves an experienced team of historians and designers. Their extensive research is the cornerstone of our replicas‘ authenticity: they consult historical sources and the relevant professional literature, and look at original weapons in private collections and the world’s museums as well. New creations for international film productions also start this way. Based on the results, the best grade of carbon steel for the planned replica (AISI 1065 – AISI 1095) is selected. Depending on the weapon required, the appropriate forging techniques are used to prepare it for hardening and tempering to between 48 and 52 HRC on the Rockwell hardness scale.

Hand forged for excellence

Forging the blade is not only the most time-consuming step, it also requires the highest level of skill from very experienced blacksmiths. Our studio keeps the long tradition of open hearth forging alive. There, the master blacksmiths constantly pass on their knowledge and skills to their able apprentices.
First, a steel blank is heated over an open hearth furnace. A variety of forging hammers pound the blank in rhythm to arrive at the required shape, cross section, length, and distal taper. The process is a repeating cycle of heating, hammering, and then cooling that ultimately changes the steel’s molecular structure, increasing its strength and hardness. This process creates a hand-forged blade that is much tougher than one made by grinding and shaping. After the blade has been hammered out to the required shape, it is ground with a range of grits and belt grinders to perfect its cross section and distal taper. At every step of the way, the quality of the blade is inspected and compared to ideal values. When the blade has been ground to perfection, it is polished by a professional polisher.

Heat-treated for authentic swordplay

The blade is now ready for the most important step: hardening and tempering (heating and cooling down under precisely controlled conditions). Our blacksmiths and a skilled metallurgist are responsible for this step. Temperature control is critical at this step, so a specially developed electric furnace is used. Depending on its length, cross section, and steel grade, the blade is heated to a specific temperature and then bathed in cooled oil to harden it. Special jigs keep the blade from warping while it is being hardened, because hardening puts a lot of stress on the steel. Tempering the blade relieves the stress. In a different custom furnace, the blade is kept at a constant, comparatively low temperature for 45 minutes to an hour. When it comes out of this furnace, the blacksmith has 15 minutes or less to complete the last step in the forging process: hammering out any residual warp.

Optimal balance between hardness & flexibility

The next inspection makes sure that the blade hardness is between 48 and 52 HRC, and that it flexes back to its original shape after being bent almost 13 cm. The values are imprecise but deliver a good indication of whether or not the blade is too hard and brittle or too soft and bendable. Our swords‘ balance between hardness and flexibility is the guarantee that each of them functions optimally and is suitable for test cutting (if appropriate for the type of sword).
After the final hand polish, the blade and its components parts from the woodworking and leather departments are sent to be assembled. Our sword grips are made of kiln-seasoned wood worked by skilled craftsmen. All of our leather scabbards are handcrafted by trained leather craftsmen. The result of this process is a thing of beauty: a completely assembled sword representing the perfect symbiosis of traditional handicrafts and state-of-the-art technology in combination with quality management in compliance with ISO 9002.