Sam Stearns -
Lead BladeSmith
Welcome to my world of custom fantasy-style swords and knives! My name is Sam Stearns, and I’ve been passionately crafting unique blades since the Covid shutdown in 2020. As an Industrial Engineer with a background in medical and telecom manufacturing, I bring a meticulous and innovative approach to my work.
I specialize in creating custom orders that reflect my clients’ visions, adding my own twist and style to each piece. My favorite part of the process is collaborating with customers to bring their dream blades to life. As a proud member of the American Bladesmithing Society, I’m currently preparing to test for my Journeyman Smith certification next year.
Every project begins with a detailed CAD model, ensuring precision and allowing for any necessary adjustments before the crafting process begins. I also offer 3D printed miniatures of each blade, providing a tangible preview of the final product. Additionally, I create custom displays to showcase each piece, blending functionality with artistic presentation.
I love experimenting with new chemical and metallurgical processes to meet the unique design specifications of each project. My expertise also extends to detailed finishing woodwork and CNC machining, allowing me to blend machine-made precision with the artistry of handmade craftsmanship. This hybrid approach ensures that every piece I create is both functional and a work of art.
Thank you for visiting my site. I look forward to crafting a blade that is uniquely yours!
Matt Stearns -
Assistant BladeSmith
Meet Matt Stearns, a dedicated knifesmith with a passion for crafting high-quality, custom knives. With a keen eye for detail and a commitment to excellence, Matt has honed his skills to create knives that are both functional and beautiful.
Matt specializes in custom knife designs, working closely with clients to bring their visions to life. Each knife is meticulously crafted, combining traditional techniques with modern innovations. From the initial design phase to the final finishing touches, Matt ensures that every piece meets the highest standards of craftsmanship.
While Matt specializes in more traditional replicas of existing historical pieces, he’s no slouch when it comes to new designs and projects. Matt prefers a more hands-on, historical approach and really has a passion for pounding steel with a hammer. (and dressing like a pirate while doing so)
Explore Matt’s latest creations, and feel free to reach out to discuss your custom knife project. Matt looks forward to crafting a knife that is uniquely yours!
Alex Stearns -
Welding Specialist
Meet Alex Stearns, a trained welder, who assists Sam with the welding of his zany tool designs. While Alex only has one 1/2 finished knife to his name, he contributes around the forge quite a bit, as some of our larger creations require both Sam and Matt to hold the steel while Alex takes the video.
His latest achievements can be seen in most videos and shots of the forge. Since most (almost all) of the tools we’re using to move steel can be quite expensive if bought outright, Sam designs up most of the tools seen around the shop, using Alex to weld anything he doesn’t want to have fall apart. After the creation of several of these tools, Alex has become quite the welder, able to weld complex assemblies together while retaining critical to function features.
He’s highly recommended to anyone looking to weld together any higher complexity/strength pieces, as he’s the go-to guy for welding anything you don’t want to have explode at a critical moment around the Forge.
