Cast in Steel

Project: George Washington’s Swords

Cast in Steel 2025 competition challenges university students to use modern casting tools to creatively design and produce a functioning version of a sword for George Washington.  His sword collection is on display in Mount Vernon: https://www.mountvernon.org/preservation/collections-holdings/washingtons-swords/ A description and interview with the expert on his swords is: https://www.mountvernon.org/preservation/collections-holdings/washingtons-swords/washingtons-swords-an-interview-with-erik-goldstein

Teams are to produce a replica of one of Washington’s actual swords or to design one based on his known preferences and needs. One new element for the competition is the plan to document it as a made for TV series to be shown on a major streaming service. The requirements and evaluations will be as in the past, but the performance testing will be done in qualifying rounds to select the finalists for a Grand Finale.  Teams will be competing in qualifying round that allows teams from the same schools to be in different rounds.  The rounds will be seeded with teams from prior winners.

Competition Requirements

Teams will perform all aspects of creating a new George Washington sword exploiting the casting manufacturing process from design conception to performance. Students are invited to submit a preliminary plan to register and get all the communications. All three (3) components of the project should be submitted.  All students must:

1. Make their version of a George Washington Sword

• • Your sword should weigh no more than 2 kg (4.4 lbs.)
  • Your sword should not be longer than 1.09 m (43 in.) in overall length.
  • This year’s item for the competition is a George Washington Sword. The 17th century Cuttoe is 23.75 inches overall length with 18.375 inches of blade length, The Silver Lion Cuttoe was 35.125 inches overall length with a 29.625 inch long blade, the Silver and Ivory Cuttoe was 36.125 inches overall length with a 30 inch blade, The French Officer’s Epee is 41.75 inches overall with a 35 inch blade,and the Alte Presentation Broad sword was 39.375 inches of overall length with a 33.5 inch long blade.
  • We require a single edged replica (ruling out the Small swords) that either match the replicas within a tolerance of 2 inches or an original sword that would be in the style and appropriate for Washington (with an explanation and defense of the design in the technical report) that is more than 25 inches long overall with at least 20 inches of blade length and less than 43 inches overall with a maximum blade length of 35 inches.

2. Document their project with a professional Technical Report of less than 30 pages supporting their decisions.
3. Produce a Project Video, not to exceed 5 minutes, that documents their project.

• Important: Please take a minute to read through the student filming guide for all the info on producing your project video—we want to make sure we can use your awesome footage in the show! Quick note: we’ll need a signed waiver, found on the last page of the guide, to use your teams footage. Any questions about the guide, please contact Luke Ellis directly at Luke@WorkaholicTV.com.      

All project components submitted for the competition become property of SFSA.

Expert Discussion

Frequently Asked Questions

• • • How many teams can one school compete with?
      As many as you like.
    • Will there be components of the judging based on mechanical numerical testing or mostly from the human component of how it feels to work with and ease of use?
      The judging will include all aspects of the sword including its functionality, durability and apparent quality. No mechanical tests will be done and no quantitative tests. The tests will be similar to the type of tests used regularly on Forged in Fire.
    • Are there any restrictions on use of outside resources?
      There are no restrictions on using outside resources. We expect you to use anything and anyone to be as successful as you can.
    • Are we required to cast the blade itself, or can we simply buy bar stock for the blade and machine and forge it into our desired shape?
      There are no minimum requirements for the type or amount of casting but the use of casting to add value is paramount. Having said that, the complexity of the sword this year, especially some of the hilts would be amenable to casting. It is reasonable to cast the blade and hilt as separate items for the sword. You are allowed to do the blade with bar stock but it would limit the competitiveness of your entry.
    • Are we able to machine the guard and handle for our sword?
      Yes. The casting requirement is open and challenges the team to use the casting process creatively to add value to the required entry. Any other manufacturing processes can be used on the casting or to provide parts needed to finalize the item. Grinding, forging, machining, heat treating, etc. are all value added steps that can be used. Adding machined parts that make sense would be fine. It would be useful in your report to describe why the machined components were used.
    • Can we use bronze material for decoration?
      Absolutely, great idea.
    • We are looking at replicating/taking inspiration from the Officers Epee, but we have a question regarding the construction of the blade. Amongst the swords mentioned in the competition guidelines, there are three types of blades mentioned: a broadsword, a cuttoe, and the epee. With these blades being different in function, will the testing be normalized in any way? For instance, with our epee, which is predominantly used as a thrusting sword, would not be as adept for slashing compared to a cuttoe.
      Our tests will include both thrusting and slashing. They indicated that thrusting benefits from a straighter blade and a well designed point and a single edged blade with curvature is superior for slashing. The cuttoe is a design optimized for both but the epee could perform well.
    • The guidelines mention that a single edged replica must be created, does that mean we would need to change the blade style for the epee? If we do so, would that be counted against us for authenticity?
      Single edge is not required and the eppe would qualify for entry.

Awards

Each sword entry will be eligible for 5 awards and a Grand Prize:

1. Best Design and Process ($200/student)
2. Best Authentic Sword ($200/student)
3. Best Casting ($200/student)
4. Best Project Video documenting the project ($200/student)
5. Best Performance based on testing and expert evaluation ($200/student)

Grand Prize based on the top 5 rankings from 1-5 above. Weighting of the scores will be (1) Design and Process 25%, (2) George Washington Sword Authenticity 15%, (3) Casting 25%, (4) Video 10%, and (5) Performance 25%  Prize money is limited to $500 per student.

Important Events and Submission Dates

All electronic submissions should be sent to Renee Mueller at rmueller@sfsa.org.
Send your Sword* to:
Renee Mueller
SFSA
780 McArdle Drive, Suite G
Crystal Lake, IL 60014
USA

*Be sure to provide a tracking number for your sword shipment.

Note about packing your sword for shipment

Either a cardboard box or cardboard tube will work well for the outer packaging.  The sword must be restrained from moving within the package.  In past years items have shown up with blades poking through the outer box – the shipping companies frown upon this, and so do we.

For packing materials, we recommend using a expanding foam packs – examples.  This type of packing material will not allow the item to move within the package.

Identify your sword

We receive items every year with no indication as to which team the item is from.  At least put a piece of paper identifying your team in the package with the sword.

Swords will not be returned

Starting this year, competition items cannot be returned.  The Grand Prize winning sword will be retained by SFSA, and the other swords will be sold at auction to support the Foundry Educational Foundation.  If your team desires to keep their sword, they should produce a second copy for that purpose.  SFSA will not return any items to teams.

Technical Report Must Contain:

Registration

Are you ready to compete? CLICK HERE to register your team for the CIS 2024 competition.

References

• View the 2024 competition – Halligan Bar
• View the 2023 competition – African Spear Point
• View the 2022 competition – Celtic Leaf Sword
• View the 2021 competition – Thor’s Hammer
• View the 2020 competition – Bowie Knife
• View the 2019 competition – Viking Axe