CAS Hanwei Brand
CAS Hanwei, originally founded under the leadership of Paul Chen at the prestigious Hanwei Forge, has long been recognized for producing some of the finest quality reproduction swords and accessories for collectors and practitioners alike. Though production has since moved from the original Paul Chen Hanwei Forge to the esteemed Dragon King Forge, the legacy of exceptional craftsmanship continues. The same skilled masters, including renowned artisans like Frenchie Jin, still craft every sword with the same dedication to quality, performance, design, and value that made CAS Hanwei a leader in the industry.
How CAS Hanwei Makes Their Sword Blades
Hand Forged
With few exceptions, CAS Hanwei’s blades are hand forged from high-carbon steel. Using coal-fired forges, the blades are heated to the perfect temperature for shaping. Skilled smiths then meticulously work to form the basic blade profile and shape.
Hand Ground
Once forged, the blades are hand ground to near their final shape. Any inconsistencies in the sword's overall shape or distal taper are corrected, and the balance is fine-tuned. The blade is now prepared for heat treatment.
Hand Finished
Following careful heat treatment (hardening and tempering) in either CAS Hanwei's digitally controlled ovens or salt baths, the blades are polished on grinders or, for higher-end swords, hand polished. Once polished, the blades are ready to be precisely fitted to their hilt components.
How CAS Hanwei Produces Their Own Fittings – In-House
In-House Design
CAS Hanwei stands out as one of the few sword makers that produces all of its fittings (handle and scabbard components) in-house. From initial design to final production, every step is handled by the masters at CAS Hanwei, ensuring the highest level of design, fit, and finish. The fittings begin life as hand-engraved wax models, from which precision molds are created to replicate the original design down to the finest detail.
Lost Wax Casting
The precision molds are used to create positive wax copies of the originals, which are then coated in a special sand mix through a multi-step process. The hardened sand casings are heated to melt the wax, leaving a cavity ready for molten steel.
Hand Fitting
After the solid steel and sand casings are broken apart, there is significant clean-up work to prepare each fitting for installation. Once the completed blade is paired with its fitting for the first time, each piece is hand-adjusted as needed to ensure a proper fit and guarantee a long-lasting, high-quality sword.
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