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The Katana: History and Traditional Techniques

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The Japanese Katana is a popular and sought-after blade, and Kult of Athena’s “healthy” arguments about our favorite type of sword always include one.  We not only appreciate the katana’s long history but also its value as a beautiful work of art. Thanks to the big screen and rise of anime, most people recognize the katana and its connection to the samurai. But few understand its true origin, or the process of how traditional swordsmiths in Japan made these historic swords. We would like to introduce you to the history of this iconic sword, walk you through the steps of traditional swordsmiths, and introduce some key terminology.

The History of the Katana

Swords have been an integral part of Japanese history for over 1,500 years. The shape, length, and blade design have all changed since Japan’s first sword, influenced by China and Korea. Swordsmiths adapted as the type of combat changed, eventually leading to the katana style that is so well-known today.

Chinese and Korean Swordsmiths Influence the First Japanese Swords

Between the 3rd and 8th centuries, Chinese and Korean swordsmiths came to Japan, bringing their sword design knowledge. The Chinese Jian was a double-edged, straight, long sword and, once in Japan, influenced the Japanese Tsurugi design. These long, straight, double-edged swords sported blades ranging from 35-39 inches, with a traditional 8-inch handle. These are the earliest representation of swords in Japan and the base where the katana evolved from.

The Legend of Amakuni Yasutsuna and the Tachi

The earliest origins of the katana design date back to the Heian period around 700A.D. This is where we meet Amakuni Yasutsuna from the Yamato Province. Yasutsuna was the head swordsmith for the Emperor of Japan at the time.

The story begins with the return of warriors from battle. Yasutsuna and his son Amakura watched as the warriors returned. Contrary to normal recognition, the Emperor passed with no sign of approval. Upon closer look, Yasutsuna noticed that most of the warriors returning carried broken and damaged swords. He knew the Emperor was not pleased and he vowed to make things right.

He and his son locked themselves away for seven days, praying to the Shinto gods. At the end of seven days, they collected the best iron sand ore. They spent the next 31 days working on a new sword that would not break as easily. At the end of those 31 days, they emerged with a single-edged curved sword known as the Tachi.

Yasutsuna and his son continued forging these new tachi swords, giving them to the warriors. When the warriors returned from their next battle, none of the blades were broken. The tachi was the precursor to the katana. The tachi is worn by warriors slung through a cord from the waist, with the cutting edge facing downward. In addition, the mei, or signature, faces away from the body.

The Mongol Invasion Introduced the Katana

In 1274, the Mongolian armies, led by Kublai Khan, embarked on a mission to conquer Japan. Japanese samurai warriors faced a disadvantage. Their tachi swords proved ineffective against the Mongol armor, with many warriors returning with broken or chipped blades.

This prompted swordsmiths to experiment with new designs, eventually leading to the modern katana design known so well. This new design featured a superior level of strength compared to the tachi, enabling warriors to defeat the Mongol armor. In addition, another change with the katana design provided an additional benefit. Unlike the tachi, warriors wore the katana with the cutting edge facing up. This enabled samurai warriors to draw their sword quicker. In turn, this allowed them able to draw the sword and strike the enemy in a single motion. This new katana sword design continued to be the favorite weapon choice of the samurai.

Industrialization, Westernization, and Sword Prohibition

As the Edo period came to an end, Japan experienced a rapid process of industrialization and westernization. This ultimately led to a shift away from the traditional use of swords. In fact, the use of swords came to a full halt with the Haitorei edicts by Emperor Meiji in 1868. The first edict forbade peasants from carrying swords. The second edict placed a limitation on when samurai could wear the swords. The final edict, in 1876, banned the wearing of swords in every situation, including by samurai, except under specific formal ceremonies.

With the ban on swords, many swordsmiths faced mandatory closure, leading to the near-extinction of katana swordsmithing. In 1906, however, two swordsmiths were appointed as imperial household artists with the intention of preserving the skills of traditional swordsmithing.

World War II Brings Additional Restrictions

At the end of World War II, the United States occupation of Japan brought additional restrictions on sword production. They disbanded all armed forces in occupied Japan. In addition, they banned the production of katanas with a sharp edge unless you had a police or government permit. At this time, they destroyed many traditional blades. However, Dr. Junjii Honma later convinced General Douglas MacArthur that authentic Japanese swords held precious cultural and historical value. This led MacArthur to change the law, banning only wartime-made weapons. This helped preserve the long-standing tradition of the katana and allowed swordsmiths to resume producing traditional Japanese swords.

The Traditional Process of Making a Katana

The traditional methods of making a katana are much different than they are today. Steel was much different in ancient Japan, meaning that the great swordsmiths required extensive knowledge of chemical metallurgy. In many cases, creating a single blade could take months or longer. While the end swords varied in style, traditional swords went through the same basic process with the following steps.

1. Creating Tamahagane, the Katana Steel

Swordsmiths began the process of creating the starting steel, known as tamahagane. The process involves smelting iron sand with charcoal in a tatara, or a large clay furnace. This furnace reaches temperatures of up to 2,500 degrees Fahrenheit. Over the course of three days and nights, tatara masters would add iron sand and charcoal to produce the tamahagane.

2. Sorting the Steel

Once the 72 hours pass, the tatara masters break open the clay furnace to expose the tamahagane. Swordsmiths work to separate the steel based on the specific carbon content, including both high and low carbon steel.

3. Tamahagane Purification

Once sorted, the tamahagane goes to swordsmiths who manipulate the steel to remove impurities. This process included heating, hammering, and folding the tamahagane up to 16 times. This enabled the swordsmith to thoroughly combine the iron and carbon and remove any impurities.

4. Forging the Specific Blade

Once the tanahagane is purified, the swordsmith heats the high-carbon steel and creates a long, U-shaped channel, creating the sword’s outer shell and blade. The swordsmith shapes the low-carbon steel, creating a snug fit into the channel that will create the core of the katana blade. Once in place, the swordsmith forges the two metals together.

5. Coating the Blade

Before firing the blade for the final time, the swordsmith covers the blade in a mixture of clay and charcoal powder, with a thicker coat along the upper sides and dull edge. This process creates the signature hamon, or wavy design. Once covered, the blade is heated.

6. Creating the Curve of the Katana Blade

Immediately after firing the blade, the swordsmith quenches the blade in a trough of water. The rapid temperature change causes contraction between the two metals, causing the katana to bend and form its distinct curve.

7. Blade Polishing

Using a series of grinding and polishing stones, a sword polisher works to create the katana’s razor-sharp edge and reveal the markings on the hamon. This process can take weeks to achieve the desired results.

8. Creating the Tsuka

With the blade complete, metalworkers and carpenters add the final touches to the handle, such as the guard and the wooden scabbard. These are then decorated with everything from leathers to stones. Once completed, the katana returns to the swordsmith for a final examination.

Buying a High-Quality, Traditional Katana

At Kult of Athena, we offer high-quality katana swords for sale. These swords are based on and inspired by the traditional swordsmith techniques and cultural and artistic value long seen in history. Browse our selection today and discover the perfect katana to add to your collection.

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