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 m (40 in.) in overall length.

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. A script will be provided to allow each team to be included in the anticipated show.

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

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.

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.

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