The latest weapon to be created on Man At Arms by master swordsmith Tony Swatton is Ichigo’s zanpakuto, Zangetsu. Bleach is a popular anime and manga series about the Soul Reaper chronicles of Ichigo Kurosaki, which has since spawned countless video games.
Overall the weapon will be about 72 inches long, mostly made of Spring Steel. He has to bathe the steel in salt baths to make sure that it doesn’t become warped while he’s forging it. A Tig Welder is used for the handle. The sharp portion of the blade will be polished while the remaining part will be oxidized black. This matches the distinctive look of Zangetsu in the series. The handle, which has an aluminum plate, is wrapped in Stingray skin (called Honzame) in a process similar to actual Katana forges. White leather is wrapped around the blade to look like the wrapping on Zangetsu and a silk ribbon will come out the back of the handle.
Watch the video below to see the entire process in full.