Craftsman and retired Marine Corps Sergeant Major Jason DiCosimo started blacksmithing simply because one of his woodworking clients needed custom metalwork. But after he forged metal for the first time, DiCosimo never stopped.
Today, DiCosimo, 47, is a self-taught blacksmith and bladesmith known for bringing fantasy knives, battle axes and swords to life through forging and metalworking. From Aragorn’s sword, Anduril, from Lord of the Rings to the Call of Duty cleaver and the Catspaw dagger from Game of Thrones, DiCosimo is up for any forging challenge — and he loves sharing the process behind his craft.
Through his social media channels, Yellow Goose Forge, the artisan blacksmith shows millions of people what’s possible with fire, steel and creativity. But forging isn’t the only craft essential to DiCosimo’s work. Over time, he’s expanded into machining and metalcasting to push his projects even further. After 16 years of teaching himself how to transform raw metal into finished pieces, DiCosimo was thrilled to discover METAL’s metallurgical bootcamp. For nearly a week at Penn State Behrend, DiCosimo learned metalcasting basics, CAD software, foundry processes and the science behind modern manufacturing from professional metallurgists. Here’s what DiCosimo shared about his journey into blacksmithing, forging and metalcasting — and how METAL unlocked new levels in his metalworking world.
Listen to this interview (10min)
How did Jason DiCosimo start blacksmithing?
I first started out woodworking. I was building all kinds of way-out-there things that attracted a lot of strange clientele who had great ideas and a lot of creativity. I had one client who asked if I could find him a set of hinges that were big and ornate with branches and leaves. I looked everywhere for him and I told him I couldn’t do it. I failed him.
He asked, “Should you just make them?”
I said, “Yeah, probably.” So I started my metalworking journey. From there, it’s just been forging steel ever since.
How did Jason DiCosimo learn forging and metalworking?
To learn how to forge, there’s really nobody to learn from. There’s a small community of craftspeople out there that do this, but they’re very tight lipped. So you have to look for opportunities to get into forges where they’re doing artist or structural projects.
Then you go to the bladesmith, who’s only doing blades, and you pick that up.
Then you’re like, “Oh, I need to weld this piece. Let me learn how to weld. I need to machine this one. Let me learn how to use a mill,” and keep going from there. Playing with metals is a good time.
How did Yellow Goose Forge become known for swords and fantasy weapons?
I started as an artisan blacksmith. I would do lots of normal blacksmith things — fire pokers, plant hangers, dinner bell triangles, candle holders — that kind of stuff. I was pushed by someone I worked with to put my projects online. So I did, and then Yellow Goose Forge caught traction and started snowballing and snowballing.
In the comments, people would ask, “Dude, can you make this? Can you make that? Can you make this sword from this video game? Can you make this ax from this movie?”
From there, it took off. I started getting contacted by movie production companies and TV shows.
What are Jason DiCosimo’s favorite blacksmithing projects?
The ones that I have no idea how to get done.
My last sword was this big, crazy, out-there fantasy sword. So you’re welding, you’re forging, you’re machining, you’re milling, you’re doing all that stuff on the lathes. Those are the projects I love. The ones you really don’t know how you’re going to do it.
I wish everybody knew the feeling of their first completed project. Whatever it is, no matter how large or small, just the first thing you make with your hands by shaping, machining, or forging metal. When you’re done, you just sit there and look at it, something that didn’t exist before — it existed in a different form. You’re taking something raw and using heat and force to make it into what you want. You can feel it, You can hold it.
That feeling is something like, “Oh my God, I made this.” It’s super cool.
Why are forging and manufacturing careers a strong fit for veterans?
Because it takes a certain type of person.
I spent 23 years in the Marine Corps. I retired as a sergeant major in South Carolina, the same place where I went in. It was an amazing, close-the-book moment. But you learn discipline, fortitude and consistency. Those translate into everything.
For service members to transition back into the regular world, it takes a person who’s not afraid to get dirty, but also not afraid to knuckle down and do equations and learn the math and measurements. It takes somebody who can really focus on what’s at hand, especially because of the danger involved. It could be very hazardous if you’re not safe, which is another thing that’s transferable from the military services. Safety is not paramount, safe training is paramount. You’re still doing it, but you’re doing it with intention.
What do students learn at METAL’s metalcasting bootcamp?
What I wanted to get out of the bootcamp was sand casting. I’m not good at it, but I can make it look really good. I’ve already gotten so many nuggets of things that’ll fix my work and make it easier with less cleanup at the end.
As far as casting goes, I learned how to properly vent molds, how to lay the molds and gate them, and how to use sprues, risers, and vents appropriately. I wasn’t able to do that before. It was always a calamity.
The education level of METAL’s instructors is top-notch. The experience is way above what I’m used to in the craft and the trades.
I was also looking forward to going to the foundry. I’ve been in foundries before. I have my own small version of a foundry, but I want to see the large scale — what it looks like and how they do it. Whether you’re doing small or large scale, it’s all the same process, the same tools. Some of the tooling might be smaller or more unique to whatever the process is, but definitely getting to the foundry is what I looked forward to the most.
How is METAL training the next generation of metal workers?
When you’re in a trade where not a lot of knowledge gets passed around, coming to a place like METAL’s bootcamp — where people are so willing to give the secrets away and impart their knowledge onto the people coming along behind them — is huge.
I want to see more competition. I want to see more free flow of collaborative ideas and passing along the skillsets. I want to expose forging to everybody and then let people who naturally want to do it come along like a lighthouse.
With METAL, all the content, all the information, all the education, all of the skills people need to cast and forge are here. How do you get it out to the masses? You put it in front of as many people as you can, and the ones who are drawn to it will come.
Why should aspiring metal workers attend METAL’s bootcamp?
I would say whether you’re looking to get your hands dirty, use new tools, or whether the calculations are your thing, everything from the desk work to the forge work is included in this bootcamp, which is the coolest part.
There’s something for everybody. I’m not a big fan of math. However, a lot of people love that kind of thing, so calculations it is.
Why is interest in blacksmithing and forging growing?
What I do in my craft, and how I present it to the world, is I’m making things that people think you can’t make with your hands. They think there’s no way you’re going to be able to make this crazy sword or battle ax. So when I show people the process from beginning to end, when they see the end product, they want to know, “how did you do it?”
The question I get most often from thousands of people every day is, “how do I learn how to do that? How do I get started?”
The hunger for people to learn forging, metalcasting and hands-on manufacturing is there. We just need to show them how.
Ready to forge your career in metal manufacturing? Explore METAL’s free online training and hands-on bootcamps to discover careers in metalcasting and forging. Visit our events page to find a bootcamp near you.
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FAQs
What is blacksmithing?
Blacksmithing is the process of shaping and forging metal using heat, tools and force. Blacksmiths create everything from decorative ironwork and tools to knives, swords and industrial metal components.
What’s the difference between forging and metalcasting?
Forging shapes heated metal using force from hammers, presses or dies, while metalcasting involves pouring molten metal into a mold to create a finished shape. Both are essential manufacturing processes used across industries including defense, aerospace, automotive and energy.
How do beginners learn blacksmithing and forging?
Many beginners start by watching online tutorials, attending workshops, or enrolling in hands-on manufacturing training programs and bootcamps. Learning forging often includes skills like welding, machining, metallurgy and shop safety.
What careers are available in forging and metalcasting?
The metal industry offers careers including blacksmithing, forging, welding, machining, foundry work, CNC operation, metallurgy and tool-and-die manufacturing. Skilled workers are needed across defense manufacturing, transportation, aerospace and industrial manufacturing.
Why are manufacturing careers a good fit for veterans?
Manufacturing and forging careers often align well with military experience because they require discipline, attention to detail, safety awareness and problem-solving skills. Many veterans transition successfully into skilled trades and advanced manufacturing roles.
What is sand casting?
Sand casting is a metalcasting process that uses compacted sand molds to shape molten metal into finished parts or components. It’s one of the oldest and most widely used casting methods in manufacturing.
Can blacksmithing become a career?
Yes. Modern blacksmiths and bladesmiths build careers creating custom metalwork, artistic pieces, knives, swords, architectural ironwork and industrial products. Many also teach classes, create online content or operate fabrication businesses.
What industries rely on forging and metalcasting?
Forging and metalcasting are critical to industries including aerospace, automotive, defense, shipbuilding, construction, medical manufacturing and energy production.
How can someone get started in manufacturing training?
People interested in forging, metalcasting and manufacturing careers can begin through free online training programs, community college courses, apprenticeships, trade schools and hands-on bootcamps like METAL’s workforce training programs.