Spraying sparks, glowing steel and hammer blows — Karim Khedira is one of the last remaining bladesmiths dedicated to one of the oldest crafts in the world. To give us an inside look at his knife-making process, Karim invited our team at HORL to his forge to witness, between the heat and the dust, how a true Damascus steel knife is created. This was a community project with the Rollschleifer Owners Club. Its members voted on the attributes of the unique piece, which was then jointly developed by Karim and Timo Horl.
Damascus steel is a type of metal made by layering and hammer-welding different types of steel together. It’s known for its strength, sharp edge retention, and signature wavy pattern.
As we entered Karim’s rustic-looking workshop in Liestal, Switzerland, we traveled back in time. Instead of digital technologies with automation and lasers, Karim opts for the old ways. For example, he uses old-fashioned equipment with foot pedals, such as a Herkules pneumatic forging machine from the 1940s. This allows Karim to forge each knife with precision, character, and a deep connection to the craft’s heritage.
We were captivated by Karim’s contagious passion for his craft and by the way he produces his pattern-welded steel masterpieces. Through his expert sense of proportion, precision, and attention to detail, Karim carries on the artistry and tradition that has endured for centuries.
Making
the Metal
In the first step of the forging process, Karim chose three different steels and looked specifically at the carbon percentages. The higher the carbon content is, the harder, stronger, and more durable the steel will be — to a point. Too much carbon, however, can make the blade become more brittle.
Other components within the selected steel, like manganese and nickel, will ultimately affect the final appearance of the Damascus steel blade. “These will give the blade its final characteristic wavy pattern,” Karim said. “The more different types of steel are being used, the more contrast the blade will later have.”
Between the high temperatures and the intense sparks, Karim cut the piece of steel into three equal lengths, layered them on top of each other and welded them into a rough billet.
A billet is a compact block of metal made by layering different kinds of steels. It serves as the starting point for forging tools, knives, or other metal objects.
Once the steel layers had been quickly welded, Karim transferred the metal block to a 1,200-degree oven for fire welding. This process allows the steels to combine completely.
After briefly removing the billet from the oven, Karim powdered the steel with borax, which creates an airtight surface that prevents oxidation and rust. Using the Herkules air hammer, Karim then forged the steel block and stretched it out to a length of approximately 50 centimeters. He then divided it into four equal parts again, which he then refolded, rewelded and reground into a new steel billet. By repeating that process of layering, welding, heating, and stretching, Karim created the striated surface patterns that Damascus steel is known for. After the third round, the stretched steel had a total of 256 layers. Karim would then forge the knife out of this final billet.,
The metallurgy behind this process is fascinating. Unlike low-carbon steels or regular stainless steel, the combination of high-carbon steel with other kinds of steel creates what are known as “carbide formations” during the heat-treating process. These microscopic structures contribute to both the durability and the beautiful banding seen in real damascus steel.
Forge of a Damascus Knive
Shaping
the Blade
Inspired by the Japanese bunka knife, this damascus knife had a beveled tip and a straight back. After Karim had defined the transition from the handle to the blade, he reduced the hardness of the steel by softly annealing it in a 700-degree oven. That way, it could be processed better. Afterwards, he used a surface grinder to provide a flat surface and reduced the thickness of the knife to about three millimeters. As soon as that thickness was achieved, Karim worked out the contour of the unique damascus during belt grinding. This step required absolute precision.
The Big Finale:
Revealing the Design
and Final Assembly
Once the blade was fully formed, it was time to sharpen it and give it a handle. Karim began by giving the knife a proper edge using a large, rotating grinding stone. After another heat treatment in an 850-degree oven, our unique piece was quenched in oil to further strengthen the blade.
Once these preliminary strengthening measures had been performed, Karim put the raw knife into the oven for another two hours. This final heat treatment helped it reach its peak level of hardness. After removing it from the oven, he started another round of sharpening and polishing, which ended with dipping the knife in hydrochloric acid to finally reveal the distinctive patterns.
As we watched the wavy striations appear before our eyes, what looked like magic to us was really just simple chemistry. The acid affects the different steels at different rates, causing the iconic patterns to emerge. Then, through a little polishing on the buffing wheel, Karim brought the Damascus pattern out in its full glory.
Finally, Karim attached the handle made from black, exclusive moor oak and performed one final grind using a #3000 grit stone. The knife was then ready, and it became incredibly clear to our team at HORL why Damascus steel knives are so prized.
The Perfect
Edge
We were now finally holding the unique knife in our hands! It was made of 256 layers of noble Damascus with a blade hardness between 61 to 63 HRC and a total length of 31 centimeters. The blade itself was 18 centimeters long. Of course, we were unable to resist the opportunity to sharpen the knife with our HORL2 sharpener. The height of the knife was perfectly suited for our sharpener. In order to bring out the whole potential of the Damascus knife, we used the extra fine whetstone of our HORL Premium Sharpness Set. The fine #6000 grit of the whetstone gave the blade its final, high-quality edge.
Strength and Precision:
the Keys to Success
“While forging, it is important to have a sense of proportion and an artistic flair,” Karim explained. “To this day, not much has changed from the original craftsmanship with the exception of the machines. It fascinates me every time, to put the raw steel in the fire and to bring the shape with my own strength in order to work out the details of my knives more and more precisely. I understand why forging knives was seen as magical, because it needs a lot of knowledge.“
– Karim Khedira
The tradition of creating pattern-welded damascus steel connects modern bladesmiths to an ancient line of artisans. Whether creating kitchen knives, hunting knives, or decorative pieces, the fundamental techniques remain similar to those used centuries ago. This unbroken tradition demonstrates why Damascus steel continues to captivate both the creators and collectors that seek exceptional beauty and performance in their bladed tools.