Each pan starts its journey as a flat, circular steel disc. The disc is pressed between a larger outer ring and a smaller inner die. This process raises the side walls and gives the steel a basic and rough pan shape.
Following the press, the blank is placed in the forge and heated to a glowing red. Blacksmiths continue to shape the sidewalls with precise and rhythmic blows on the anvil.
When the side walls are of even height and pitch the pan returns to the press where the base is flattened under fifteen tons of pressure. Fine adjustments are made with a lever and hammer blows.
Once the pan base has cooled it is passed along to clean-up and assembly. The sharp edges of each pan are taken down with grinders and smoothed to an even radius.
Handles are shaped on the anvil and hammered to match the curvature of the pan's sidewall.
Holes are drilled and the handles are riveted in place.
Clean Up & Seasoning
After the pan is fully assembled it is placed in the sand blasting cabinet. Aluminum-oxide combined with high-pressure air blasts the surface of the metal removing mill scale and surface imperfections.
A wire-brush then polishes the surface, restoring the surface to an even and smooth finish.
At this stage the steel is very reactive to moisture and oxygen. Left in this state the steel will begin to rust. To create a protective barrier the pans are placed in a kiln and baked at high temps for forty minutes.
Under this high temperature the steel reacts and builds a layer of iron-oxide on its surface. This reaction produces the familiar blue-ish black tones of the final product. While the pans are still hot, coconut oil is applied and allowed to pull into the pores of the metal as it cools.