Seven competitors return to the forge for a second chance at glory and redemption; they'll have to create four different weapons and survive four rounds of testing; the smiths begin outside using the dreaded coal forge.
The four remaining smiths are tasked with crafting an elegant Yemeni dagger; the intricacies of the dagger prove to much for one; while an intense round eliminates the second; the two finalists must choose the weapons they will forge at home.
Four bladesmiths honor American presidents by forging a replica of Teddy Roosevelt's Rough Rider Bowie; the remaining two smiths move on to their home forge to re-create George Washington's colichemarde.
For the 100th episode, four bladesmiths are tasked with forging a chopper and must choose from a mammoth pile of metals and materials from all previous 99 episodes; the two finalists head home to re-create the O-Katana.
Four smiths must use the canister method to forge a signature blade, but welding failures and abandoned leave some odd the competitors scrambling; two smiths return to their home forges to create the Austro-Hungarian Hussar Saber.
Four bladesmiths must forge a blade using steel harvested from a vintage pinball machine; two smiths advance and return home to build a weapon rooted in savagery; the Barbarian Sword.
Four bladesmiths must forge friction folders from a rusty pickup truck; the two smiths left standing head back to their home forges to recreate an exotic weapon wielded by ancient Southeast Asian warriors; the Javanese Kris.
Four bladesmiths are tasked with re-creating the Fairbairn Sykes fighting knife by combining three sizes of W1 round stock; two smiths must forge Japanese Gen. Yamashita's gunto.
Four bladesmiths must forge signature blades from different sizes of spring steel; two smiths survive an intense round of testing and return home to re-create a Greek kopis.
In a special five-part competition, top bladesmiths from each branch of the US military - Army, Air Force, Marines and Navy - compete to earn a spot representing their branch in a battle for our biggest prize ever: ,000. Round one belongs to the Army, as four soldiers must forge a special forces V-42 stiletto. After a ruthless bout of testing, two smiths are dispatched to their home forges to build a US Army Officer's Sword. The winner secures a place at the Army Anvil competing in the Battle of the Branches finale, where victory brings pride, glory, and a ,000 grand prize.
In Round Two of the Battle of the Branches Tournament, four airmen from the US Air Force must forge a Bolo knife using the San Mai technique to combine high carbon steel with helicopter parts. Shaping these massive pieces of uncooperative metal into useable steel will take all of the airmen's ingenuity. After rounds of close inspection and brutal testing, two smiths return home to forge a weapon that exemplifies their branch: the Air Force NCO Sword. Which airman's blade will land him a spot at the Air Force Anvil, and a chance at the ,000 grand prize?.
In the third round of the Battle of the Branches, four Marines are tasked with forging the KA-BAR. As an additional challenge, these smiths must adapt and overcome to forge together metals from a massive anchor using the San Mai technique. After a punishing round of testing, the two surviving smiths return home to forge the Marine Corps Officers Sword.
Four U.S. Navy officers must forge a multipurpose naval Mark 3 dive knife with metal from a giant anchor chain; two sailors return home to re-create the intricate and iconic naval officer's sword.
Master bladesmiths are challenged to re-create some of history's most iconic edged weapons, then a panel of judges tests the weaponry and decides who is the “Forged in Fire” champion.
Four bladesmiths are tasked with forging signature blades from gym equipment; after a severe round of testing, the two that remain have only four days in their home forges to re-create one of Japan's deadliest swords: the Nagamaki.
Four bladesmiths are tasked with forging fantasy blades from a meteorite, battling difficult forge welds, they create their one of a kind blades; the final two head to their home forges to re-create a legendary weapon: Attila the Hun's Sword of Mars.
Bladesmiths fight fire with fire when they use a dismantled forge's steel to construct a blade; the smiths struggle to salvage enough material to create a san mai billet; two return to their home forges with four days to recreate the Partizan.
Four bladesmiths face triple the challenges when they must forge a canister Damascus blade from three different steels using three separate cans. Keeping their canisters and blades straight proves easier said than done, and Round 1 gives one of the competitors a tough break. After a rough round of testing, two finalists head back to their home forges to recreate two of history's most reliable hunting weapons: the Messer and Bi-knife.
Starting with four bladesmiths, they are tasked to forge a kukri without power tools. The remaining two after the elimination round must make a Ram Dao, which is known as a sacrificial sword in South Asia.
Bladesmiths are tasked with forging blades from old toys using the san mai technique; two smiths return to their home forges to re-create an iconic American blade: the M1832 foot artillery sword.
On the 50th anniversary of the first steps on the moon, bladesmiths compete to re-create a space-age M-1 NASA survival knife out of ball bearings; only bladesmiths with NASA-worthy engineered blades will to return home and construct a spiked mace.
It's a battle royale for four bladesmiths when they are tasked with forging signature blades with an integral knuckle duster from a steel cage and barbed wire; Two bladesmiths must recreate one of Scotland's most famous and feared weapons.
Four bladesmiths are given a special assignment when they are tasked with forging Doug Marcaida's favorite blade, the Karambit; Two bladesmiths return home to re-create a weapon that's both deadly and debonair: The Cane Sword.
Four bladesmiths must scavenge a construction site to salvage their own knife-making materials; after a critical error sends one competitor home, the three remaining bladesmiths move on.
The odds are stacked against four bladesmiths when they each forge a chopper in a distinct Damascus pattern; two smiths return home to re-create one of the most widely used and dangerous medieval weapons, the falchion.
Four bladesmiths must start at the bottom when they are tasked with creating ladder pattern damascus knives from a real ladder; the remaining two smiths head home to re-create a battle sword.
A quartet of bladesmiths are tasked with making canister damascus using barbershop tools, but before the knife making can begin, they must harvest their cans from an old barber's chair. Things get hairy as one competitor must restart with only 45 minutes left. Then, after an intense round of testing, the remaining two competitors head back to their home forges to re-create a weapon that's as fierce as it is fine: the Bhuj. Which smith's blade will make the cut, earning the title of Forged in Fire Champion and a check for ,000?
It's anchors aweigh, as four bladesmiths are tasked with forging a Pirate's Boarding Axe from a treasure chest. They must batten down the hatches as they battle wayward welds and forging fiascos that leave two smiths high and dry. The final two smiths return to their home forges to recreate the legendary weapon carried by history's most notorious pirate: Blackbeard's Cutlass. Who will seize the ultimate treasure of ,000 and the title of Forged in Fire Champion?
In this special kung fu competition, four bladesmiths square off in the Forged in Fire dojo where they must make a matching set of three kunai throwing knives. Only true smithing masters will be able to create three completely identical knives in a short three hours. Each smith has their own strategy of attack, but only two make it through and head back to their home forges, where they are tasked to recreate the legendary 9-Ringed Broadsword. Which smith has the chops to defeat the competition, earning the title Forged in Fire Champion, and a check for ,000?
Four smiths hit the fast track when they are tasked with forging signature blades by salvaging materials from a go-kart. There's no pumping the brakes as the smiths navigate a winding road of welding mishaps, which ultimately send two smiths home. In one last drive on the road to victory, the two remaining competitors have just four days to recreate the favored sword of one of the most notorious leaders in history: Genghis Khan. Which smith will join the ranks of Forged in Fire champions and return home with the ,000 prize?