Forged in Fire

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.

• Wil Willis (seasons 1–7) is a former Army Ranger (Third Ranger Battalion) and decorated Air Force para-rescue specialist.[1][3][7] Willis' previous television experience includes Special Ops Mission and Triggers, two series that aired on the former Military Channel.[2]
• Grady Powell (season 8–present), a former U.S. Army Green Beret, replaced Wil Willis as the show's host as of the Season Eight premiere on November 18, 2020. Powell's previous television experience includes two seasons starring on Dual Survival on the Discovery Channel.[8]

• J. Neilson, a knife and sword expert,[1] holds the rank of Master Smith within the American Bladesmith Society (ABS). He has over 20 years' experience in making knives and edged weapons.[2][7] He examines the weapons' technical qualities and tests their durability.[3] In Season 3, Neilson took a leave of absence to have surgery on his hand and returned in later episodes of Season 4.
• David Baker, a Hollywood prop maker who has appeared on the Spike TV series Deadliest Warrior,[3] is an authority on weapons history[1] and an expert on replicating period-accurate weapons for both museums and films.[2][7] He judges the weapons' historical accuracy and aesthetic beauty.[3]
• Doug Marcaida, an edged-weapons specialist, is a U.S. military contractor, martial arts instructor, and knife designer for FOX Knives Italy. Specializing in the Southeast Asian fighting style of Kali, he has taught classes in weapon awareness and use for military, law enforcement, and security organizations. He also designs "the most dangerous knives in the world", owns and sells his own line of knives.[9] Marcaida evaluates the smiths' weapons to determine their effectiveness in combat with his famous kill tests. His catchphrase is to declare of a worthy weapon: "It will KEAL" (i.e., "Keep Everyone Alive"). He also tests the weapon's sharpness and if deemed worthy, receives the declaration "It will cut". When he is unable to test weapons himself due to injury, Marcaida brings in his brother R.J. or one of his students to perform the task in his place.
• Jason Knight, another ABS Master Smith, filled Neilson's seat on the judges' panel during his medical absence in Season 3. Neilson appeared alongside Knight for the Season 4 premiere; Neilson resumed his seat in the eighth episode.
• Ben Abbott, a nine-time Forged in Fire champion as of February 2022, debuted as a judge starting with the 21st episode of the fourth season. Abbott would replace Neilson in some episodes after Season 5 and replace Baker when Baker participates in the final round in Super Champion Edition (Season 7) and Beat the Judges episodes. In season eight, Ben took on multiple opponents in a five-part "Beat the Unbeaten" series. He remained undefeated and brought his record in the forge to 9–0. Abbott remains the only undefeated judge, save Jason Knight who never participated in the competition. Neilson lost in a Beat the Judges episode, and Baker lost in the Super Champion Edition episode.

Tim Healy and Steve Ascher are executive producers for History.[1][7] Jodi Flynn, Brent Montgomery, David George, Shawn Witt and Simon Thomas are executive producers for Outpost Entertainment.[1][7] Healy observed the demonstration, and later the filming, from the sidelines. Healy says that the inspiration for Forged in Fire came from his and other developers' love of food competition shows such as Chopped and Iron Chef.[3] However, in order to appeal to the History channel's audience, they decided to have the competition focus on historical weaponry.[3]

Typically, candidates for Forged in Fire episodes go through a casting call and screening process before appearing and competing on the show. For example, Doug Marcaida shared a casting call to his Facebook page on October 18, 2021, seeking "...metal workers to forge iconic edged weapons from History!".[11] After applying to be on the show, the potential competitors are interviewed by video and phone; asked questions about their metallurgy knowledge, experience, and skills; and undergo background checks. Sometimes, the entrants are asked to build a weapon with particular specifications, with progress pictures being sent to and analyzed by the show's producers before being considered to compete on an episode.[12]

On occasion, former contestants are invited back to the show to participate in another competition. As examples, bladesmiths have reappeared and competed in a military branch tournament, "Second Chance Tournament", or a broken blade "revenge" episode, just to name a few.

Forged in Fire episodes are filmed at Brooklyn Fireproof Stages in Brooklyn, New York City, New York, in a safe, professional environment.[13]

The set is composed of a large judge's table from where the judges spectate throughout the episode, a separate worktable for each contestant, large shelving units dubbed the "pantry" for various handle materials, and large quantities of various metal types, grades, sources, and shapes. The rest of the set floor is spotted with other work stations for tools and equipment such as Venturi forges (made and supplied by Majestic Forge[14]), a variety of hammers, steel files, wire brushes, anvils, foot-operated power hammers, hydraulic presses, electric buffer wheels, grinding wheels, vises, welding machines, and other hand and electric tools.[15] Safety equipment is also found throughout the set and is used during construction and testing of weapons.

The winning blades from each episode are showcased on the "Winners Wall" of the filming studio. Some of those blades can be seen on the wall behind the standing contestants during testing portions of various episodes. As the show's sign of respect and gratitude for the participant's effort, time, and labor that went into making each weapon, non-winning blades are returned to the competitors after the respective episode has aired.[12]

The "Master & Apprentice" episode in Season 4 featured four master/apprentice pairs of smiths. Only one member of each pair was allowed to work at any time, trading off every 30 minutes in the first two rounds and every day in the third. The non-working member was allowed to offer advice. For this episode, the forging time in the first round was extended to three and a half hours.

The "Ultimate Champions Edition" (Season 4) and "Rookies Edition" (Season 5) each featured five smiths instead of four. The smiths were required to forge a particular type of blade at their homes and bring those weapons to the studio for a preliminary test. One smith was eliminated based on the results of this test, after which the competition proceeded through the normal three rounds.

On October 3, 2018, a five-week Invitational Tournament premiered, consisting of four preliminary heats and a finale. Four smiths with a particular specialty (farrier, armorer, blacksmith, metalworker) competed in each preliminary heat, with the winners advancing to the finale for a $50,000 prize. Dave Parthemore of Connecticut won.

A "Battle of the Branches" tournament began on May 8, 2019, with four smiths from a different branch of the United States armed services (Army, Navy, Air Force, Marines) competing in each preliminary heat.

During the 2019 season, Forged in Fire aired "enhanced" episodes called Forged in Fire: Cutting Deeper, which featured bonus scenes of older episodes with expert tips and techniques from the judges like Dave Baker explaining what happened to each blade during the weapon tests. Each episode was two hours long (made up of 2 older one-hour episodes), highlighting blade themes such as "Revolutionary War Swords" and "Curved Blades", etc.

On May 13, 2020, a special episode titled Forged in Fire: Meet the Judges aired at 8/9c on History. The judges J. Neilson, Dave Baker, and Doug Marcaida, were in the "hot seat" as fans asked them questions about the show, their personal lives, and bladesmithing techniques.

On November 24, 2021, a special episode titled "Bladesgiving" aired at 10 p.m. EST on History. Before the Thanksgiving fest, comes the hunt in which the Forged In Fire team showcased classic hunting weapons. The episode relived five showdowns between championship hunting blades, bows and spears made by some of the forge's bladesmiths.

Aside from viewing Forged in Fire episodes on History's cable channel and its internet website, there are other subscription options to watch the show. On October 1, 2021, seasons 1, 2, 3, 6, and 7 were added to Discovery+, with season 4 being added to the streaming platform on February 1, 2022.[17] On November 21, 2021, Netflix began airing episodes, albeit one season at a time.[18][19] There are three seasons (87 episodes) available on Hulu.[19] Episodes from all seasons are available on iTunes, Amazon Prime Video, Google Play, and Vudu on a "Buy/Rent" basis.[19]

In the city of Cohoes, New York near Albany, a man, inspired by the series, tried to forge a piece of metal over a fire in a barrel near his home. He caused a fire that destroyed three residential buildings and damaged 28 others.[21]

On April 17, 2018, a spin-off series titled Forged in Fire: Knife or Death premiered on History. This series is hosted by Bill Goldberg and co-hosted by Tu Lam, a martial arts expert and retired member of the Green Berets.

On June 3, 2020, another spin-off series titled Forged in Fire: Beat the Judges premiered on History, hosted by Willis. On each episode, three previous Forged in Fire champions return to compete for an opportunity to face one judge (Neilson, Baker, or Abbott) and win another $10,000. For the first round (level 1), the three smiths each brought one weapon to the Forge in a style of their choosing and created at their home forges, and submit them for testing by Doug Marcaida. The second round (level 2) follows the same format as the third round in a typical Forged in Fire episode. However, the two remaining smiths are given only three days to forge an example of the featured weapon at their home forges. In the third round (level 3), the last remaining smith and the competing judge are given eight hours to create a fully functional example of a particular weapon type in the Forge, including handle fitting and grinding/sharpening/polishing. The other judges then test the weapons and choose the $10,000 winner. The competing judge is announced at the start of the third round; if he wins, the prize is donated to the charity of his choice. J. Neilson (Melanoma Foundation), Dave Baker (Breast Cancer Research), and Ben Abbott (Black Horse Forge: free blacksmithing classes to First Responders and Veterans).