Our Process | From Sketch to 5-Star Reviews
At Everest Forge, our process is a blend of artistry, precision, and dedication. Each blade that leaves our workshop is the result of hours of skillful forging, attention to detail, and the use of high-quality materials. Our goal is to ensure that every customer receives a product that not only meets but exceeds expectations. Here’s a step-by-step breakdown of how we turn raw materials into functional works of art.
1. Concept and Design – Where Ideas Take Shape
Our journey begins with your vision. Whether you’re looking for a custom-designed sword, knife, axe, or cleaver, our team listens carefully to your ideas and preferences. We work closely with you to develop a concept that blends traditional forging with modern functionality. The design process is an essential part of what makes each piece unique.
Key Features of the Design Phase:
- Custom design tailored to your needs
- Collaboration with customers for unique ideas
- Use of historical inspiration for swords, knives, and more
2. Selecting Premium Materials – Quality at the Core
Once the design is finalized, we source the best materials for your blade. At Everest Forge, we prioritize the quality of every material used, ensuring that your knife or sword is built to last. We use 5160 leaf spring steel and other high-quality carbon steels, all of which are selected for their durability, strength, and ability to maintain a sharp edge.
Materials We Use:
- 5160 Leaf Spring Steel: Tough, durable, and flexible
- Rosewood: For beautifully forged handles
- Leather: Various color options available for sheath customization
- White Wood: A lighter, elegant wood for handles
- Horn: Premium quality for a rugged, natural aesthetic
- Bone: For a traditional and natural feel
- Micarta: Strong, durable, and lightweight, ideal for outdoor use
- G10: Tough and durable, perfect for tactical and rugged applications
- Kydex : Various color options available for sheath customization
3. Hand-Forging – The Heart of the Forge
The heart of Everest Forge lies in the hand-forging process. Skilled blacksmiths heat the steel to precise temperatures, then hammer and shape it to perfection. Each blade undergoes a rigorous forging process, during which it is carefully tempered and quenched to achieve the perfect balance of hardness and flexibility.
Hand-Forging Process:
- High heat treatment for steel
- Hammering and shaping to perfection
- Precision cooling and tempering to enhance durability
4. Precision Grinding and Sharpening – Ensuring Sharpness
After the blade is forged, we move to the grinding and sharpening phase. This is where precision takes center stage. Our blacksmiths use a combination of hand tools and machinery to achieve a razor-sharp edge. We ensure that every knife, sword, or blade is honed to perfection, whether it's a machete for outdoor use or a dagger for display.
Sharpening Features:
- Razor-sharp edge for everyday use
- Detailed attention to blade geometry
- Use of precision grinding techniques
5. Handle Forging – Designed for Comfort and Control
The handle is an essential component of any blade. We forge handles that are both functional and aesthetically pleasing. Whether it’s rosewood, buffalo horn, bone, micarta, or G10, we ensure that each handle is ergonomically designed to offer comfort and control.
Handle Materials:
- Rosewood: Elegant and durable
- Bone: For a traditional look
- Buffalo Horn: Premium, rugged, and stylish
- White Wood: Lighter and visually appealing
- Horn: Natural, strong, and aesthetically rich
- Micarta: Strong, durable, and easy to handle
- G10: Lightweight and resilient, suitable for heavy use
6. Final Assembly and Testing – Perfection in Every Detail
Once the blade and handle are ready, the final assembly begins. The blade is carefully fitted into its handle, and all fittings are secured. After assembly, each blade undergoes a thorough inspection and testing process to ensure it meets our high standards of quality. We test the blades for their functionality, durability, and edge retention.
Final Touches:
- Final inspection and quality check
- Functional testing for durability and performance
- Detailed polishing for a flawless finish
7. Scabbard & Sheath – Protecting Your Blade
At Everest Forge, we offer a wide range of scabbards and sheaths to protect your blade and ensure safe carrying. You can choose from Western leather scabbards, traditional wooden scabbards wrapped in leather, Kydex scabbards for rugged, tactical use, or other personalized options, depending on your preference.
Scabbard and Sheath Materials:
- Leather: Available in different colors to suit your style
- Wooden Scabbards: Wrapped in leather for a traditional touch
- Kydex: Ideal for tactical, waterproof, and durable storage
- Custom Options: Personalized designs based on your specifications
8. Packaging and Shipping – Ready for You
Once your blade has passed our rigorous testing, it’s carefully packaged and shipped directly to you. We understand that your purchase is an investment, so we take great care in packaging your blade securely to prevent any damage during transit. We ship using DHL Express Delivery to ensure that your order arrives safely and on time. As part of our commitment to transparency, we also provide you with a tracking number to monitor your shipment every step of the way.
Packaging:
- Secure packaging to ensure safe delivery
- Ready-to-use blades upon arrival
- Customer satisfaction guaranteed
- DHL Express Delivery for quick and reliable service
- Tracking number provided for every order
9. 5-Star Reviews – The Ultimate Test
Our process doesn’t end once your blade is shipped. At Everest Forge, we are committed to delivering exceptional products, and we take pride in the feedback we receive from our customers. A 5-star review means that we’ve succeeded in our mission to create the perfect blade — one that stands the test of time and performs at the highest level.
Customer Feedback:
- Real-world use cases and customer stories
- High ratings for craftsmanship, design, and performance
- Testimonials about the durability and quality of the products
10. Complaint Handling, Returns & Replacements – Your Satisfaction is Our Priority
At Everest Forge, we are dedicated to providing high-quality products and excellent customer service. If for any reason you are not satisfied with your purchase, we offer a return and replacement policy to ensure that you have a seamless experience with us. We accept returns for unused items within 30 days of receipt and offer replacement for defective or damaged products. Simply reach out to our customer service team, and we’ll guide you through the process.
Complaint Handling and Return Policy:
- Easy returns within 30 days of purchase
- Replacement for damaged or defective products
- Dedicated customer support for complaint resolution
- Hassle-free process to ensure satisfaction