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The Art and Science of Damascus Steel

Surrounded by mystery, Damascus steel has a legendary reputation. Historical accounts describe original Damascus swords capable of cutting through another sword while still severing a falling hair. Its precise production method was lost in the early 1800s, giving Damascus steel a near-mythical status.


At Hometown Knives, we honor that tradition using the finest modern steels and alloys, including 15N20, 1095, and 5160. These alloys are heated, forge-welded, folded, and forge-welded again to create a laminated material that combines the best qualities of each component. The softer 15N20 provides ductility, while 1090 and 5160 give hardness and toughness. Combined with careful hardening and tempering, the result is a blade that is both highly functional and visually striking.

Damascus blades feature over 352 Layers of alternating layers of High Carbon and High Tensile.  The beautiful patterns are aesthetically pleasing, but functionally every forged blow aligns the micro grains to refine the steels and improve wear performance.  Proper heat treatments harden the blade to ensure the blade will perform in field. 

Over time, we’ve expanded our materials to include D2, 12Cr3Mo, Sanmai combinations of Damascus, and High Carbon 1095 steels, balancing artistic beauty with exceptional functional performance.

 

Premium Build Quality

Each Hometown Knife is handcrafted with precision and care:

  • Hand-forged blades balanced for optimal handling

  • Ergonomic handles crafted from exotic hardwoods such as wenge, padauk, Himalayan cedar, olive, and more

  • Custom inlays and spacers using green-and-blue turquoise, deep red sandstone, and glow-in-the-dark resin for a unique, luxurious look

  • Expert polishing and shaping for comfort, durability, and elegance

  • Rigorous quality checks throughout production

Blade Care & Maintenance

Proper care ensures your knife lasts generations:

  • Always hand wash with mild soap and warm water; never use a dishwasher

  • Dry thoroughly after washing to prevent rust or staining

  • Oil carbon steel blades regularly with food-safe mineral oil

  • Sharpen with a whetstone or professional honing service

  • Store properly in a sheath, knife block, or case — ⚠️ avoid long-term storage in leather sheaths, which can retain moisture and cause corrosion

  • Avoid cutting on hard surfaces such as stone or glass

Note: Damascus steel is high in carbon and can rust in acidic or wet conditions. Clean, dry, and lightly oil the blade for long-term preservation.

Damascus Process Overview

  1. Plates of 1090 High Carbon and 4340 / 5160 HT are stacked and tack welded

  2. The stack is heated in the forge until glowing orange

  3. Forge-welded under hammer pressure

  4. Profiled and cut while normalized

  5. Heat-treatment: preheated to 1500°F, soaked, quenched in oil, then tempered twice at 400°F

  6. Ground and polished from low to high grit for a mirror finish

  7. Leather sheath hand-formed, stitched, and fitted

440C Knife Process

  1. Bar stock annealed if too hard

  2. Plate straightened, profiled, and cut

  3. Handle holes drilled for balance

  4. Blade heat-treated and tempered for maximum hardness (> 57HRc)

  5. Handle scales, bolsters, and pommel fitted, ground, and polished

  6. Saw teeth and grip grooves added

  7. Final polishing to mirror finish

  8. Leather sheath hand-formed, stitched, and finished

  9. Many Stainless Knives are Hand Engraved using hardened chisel and hammering

Warranty & Refunds

  • We do not offer refunds, but provide replacement or store credit for defects

  • Lifetime Warranty covers manufacturing defects in the steel blade only, including cracks due to delamination or porosity

  • Warranty does not cover maintenance-related issues, rust, corrosion, or damage from misuse or excessive force

  • Proof of purchase required

Customer Relations & Mission

Hometown Knives is a family-owned business based in Madison, WI. We strive to provide products that can be handed down for generations. Profits also support charities that improve access to food, shelter, and quality of life worldwide.

Forge videos: Instagram @hometownknives

Location & Contact:

Hometown Knives

915 Enterprise Dr, Verona, WI 53593

Cell: 608-215-1112 (Asad)

Email: info@hometownknives.com

Damascus Steel Patterns

  • Rain Drop
  • Banded Ladder
  • Fireball
  • Twist
  • Sanmai with Ladder
  • Sanmai with Raindrop
  • Cumai - Copper Based Damascus

Important Note

Hometown Knives are tools for functional use; they are not intended as weapons.