This audio is generated by AI, so pronunciation and expressions may not be fully accurate. The narration is only in English.
The making of a Japanese katana involves two major stages. In the first stage, iron sand is smelted into tamahagane, the steel used to craft Japanese katana. In the second stage, the tamahagane is forged and shaped into the finished sword. The first stage is carried out by the murage, while the second is performed by a swordsmith.
Today, most swordsmiths craft their swords using tamahagane they have obtained through commercial means. Hirata Sword Smith, however, has insisted on producing its own steel since its founding in 2019. While initially, Sukehira handled the entire process himself, it was Nodoka who eventually succeeded him as murage.
"Traditionally, it's a master-apprentice relationship, but I can be quite stubborn, so after learning the basics, I studied on my own and honed my skills."
Was it difficult for a woman to step into a world so deeply rooted in traditional culture?
"It's an industry that's facing a shortage of labor and successors, so they welcomed me very warmly."
Tamahagane is made using a special method known as tatara smelting. The bottom of the furnace is coated with moistened clay, upon which the tatara structure is assembled and left to dry completely over the course of a week. This then becomes the furnace, with iron sand and charcoal added in turn, and air blown in to keep the fire going for about 12 hours. The work demands remarkable perseverance and concentration.
"Since iron sand and charcoal are both natural materials and their quality is inconsistent, I decide when and how much to add by looking at the color of the fire and listening to the sound of the air. It's not really something you can turn into a manual, but that's exactly what makes it so captivating."
It is precisely for this reason that they must approach each session with dedication, building experience and continually refining the craft.
Adding charcoal and lighting a fire. Photo: courtesy of Hirata Sword Smith
Removing impurities through the furnace's haguchi (air inlet). Photo: courtesy of Hirata Sword Smith
The tatara furnace is dismantled after smelting is complete. Photo: courtesy of Hirata Sword Smith
Handcrafted fire tongs.
A part of the tamahagane made through tatara smelting.
Dogu (traditional Japanese clay figurines) made during breaks between work.
Hirata Sword Smith is located in Ome City, Tokyo.
"It's precisely because we smelt the tamahagane with our own hands that we can get closer to the kind of Japanese katana we aspire to create," says Sukehira.
"The Japanese katana has a history of over 1,000 years. Swords with stronger decorative elements began to emerge during the peaceful Edo period (1603-1868), but I craft swords that stay true to their original functionality. There is a singular beauty in things that are highly functional."
The Japanese katana developed as a weapon. While it is often perceived as highly lethal, with its sharp cutting edge, Sukehira disagrees.
"I see it as a highly defensive weapon. If the sole goal were lethality, then a straight, double-edged sword like those found in the West would be more effective."
The Japanese katana, on the other hand, is single-edged and curved.
"This is because it was designed with defense, rather than offense, in mind. Its shape allows for better maneuverability, and it is the most effective at deflecting bullets, arrows, and spears. It also doesn't hinder movement during retreat. To me, the Japanese katana is a very sophisticated weapon, one that protects the wielder."
The difference between Japanese katana and Western swords is a topic that has drawn interest amongst those in foreign countries as well. Hirata Sword Smith actively shares content on social media, alongside English translations—a strategy that has proven effective, with as much as 90 percent of their recent orders coming from overseas, particularly Europe and the USA.
"We're getting more study tours and people participating in workshops. Tokyo gets a lot of international tourists, and I think it's because we're located in the city that so many of them are inclined to extend their travels here to Ome (in western Tokyo)."
The journey to the Hirata Sword Smith, as surrounded as it is by lush nature, is also an opportunity to experience a different side of Tokyo's charm, beyond the city center.
Nodoka: "I often find myself dissatisfied with my own work, even when the swordsmiths say we did good this time." And Sukehira: "We want to promote Japanese katana culture." The two will continue to work together to promote traditional Japanese craftsmanship, from Tokyo to the world.
