Forged in Fire

The set, referred to as "The Forge," is stocked with a wide range of metalworking equipment, including propane forges, coal forges, grinders, power hammers, and hydraulic presses. Medical personnel are present to treat any injuries or other health problems and may, at their discretion, disqualify smiths who are unable to continue safely. At the end of each round, the smith whose weapon is judged to be the least satisfactory must surrender it and leave the competition. In a typical episode, the four smiths are presented with a quantity of steel that they must use in the first round to forge a blade in a style of their choosing. In some episodes, they all begin with the same starting material; in others, they may choose from an assortment of metal objects or must salvage their material from a source such as a junked car or lawnmower. The host states one set of criteria concerning blade or blade/tang length, and often a second set for a feature that must be incorporated, such as serrations or a fuller groove. The smiths are given 10 minutes to sketch out their designs, followed by three hours to forge the blades; they need not adhere to their original designs. Once the time expires, the judges evaluate the blades based on the host's criteria and inspect their craft, quality, and design, then deliberate privately before announcing their decision. Any smiths who fail to meet the criteria or who fail to turn in a blade at all are subject to immediate elimination. For the second round, the three remaining smiths are given an additional two (originally three) hours to turn their blades into fully operational weapons. They must attach a handle, choosing from a range of provided materials, and incorporate any additional special features stated by the host. They must also grind, sharpen, and polish the blades, and may address any flaws or issues pointed out by the judges in the first round, if they choose to do so. After the time expires, the judges put each weapon through a series of tests to gauge properties such as sharpness, durability, and ease of use. For these tests, the weapons are used to chop/slash/stab objects that include ropes, ice blocks, animal bones/carcasses, and metal plumbing pipes. If one weapon suffers a catastrophic failure, defined as damage that renders it unsafe or ineffective for further testing, its maker is immediately disqualified. In the case of catastrophic failure by multiple weapons, the worst performer is eliminated. The judges may, at their discretion, choose not to subject a weapon to a particular test if it is sufficiently cracked or flawed. In the third round, the two remaining smiths are shown a historically significant (and technically difficult) weapon, mostly prepared by David Baker, and are given four (originally five) days to create a version of it. They return to their home forges to do the work and must comply with any specifications set by the host. Afterward, they return to the Forge and submit their weapons for testing against objects and environments similar to the historical scenarios in which they were typically used. Based on the test results, the judges select one smith to receive the $10,000 prize and the day's championship title. Rule changes Some episodes have incorporated modifications to the rules, as follows: • Extension or omission of the 10-minute design period in the first round. • Omission of a required special feature in the first round. • Not revealing the purpose of the blade in the first round. • Extension or shortening of the three-hour forging time in the first and/or second rounds, depending on the difficulty level of the blade design and any special features. • Shortening of the three-hour time to attach a handle in the second round to two hours. • Requiring the smiths to forge a blade of a specific style in the first round. • Omission of the requirement to attach a handle in the second round. • Shortening of the working time from five days to four in the third round. • Testing of weapon properties after the first round. • Stopping the clock or keeping it running if a contestant needs medical attention • Starting the episode with five smiths who all bring their own blades, then immediately going into an elimination test == Personnel ==