Making and maintaining forging tools and aids — Planning and preparation

Parent programme: Making and maintaining forging tools and aids Module: Planning and preparation Target learners: Vocational learners, apprentices and trainees in Blacksmithing, Artist blacksmithing and Metalwork Selected jurisdiction: United Kingdom — England Language: English Level: Vocational foundation to intermediate, suitable for supervised Level 2–3 learning Authority check: 1 September 2026 Course status: Open educational draft for expert review Open licence: Course text is intended for reuse under Creative Commons Attribution-ShareAlike 4.0. Embedded Wikimedia Commons files retain the licences stated on their file pages. Embedded YouTube videos remain third-party media and are not relicensed by this course.

Safety boundary: This module teaches planning and preparation. It does not authorise you to light or operate a forge, use powered machinery, carry out grinding, heat treatment, welding, thermal cutting, lifting operations or test striking tools without competent supervision and workplace permission. Current official rules, the employer's risk assessment, manufacturer instructions and workplace procedures always take precedence over this aiMOOC.

For occupational-safety law, the Health and Safety Executive guidance cited here applies in Great Britain and therefore in England. This course does not present Northern Ireland law. The vocational-training references are for England. No automatic equivalence with qualifications, licences, standards, job titles or legal duties in any other country is claimed.

Introduction

Making and maintaining forging tools and aids is a core part of professional blacksmithing. A smith may need Tongs that hold a particular section securely, a Punch and Drift for a specified hole, a Hardy tool for the anvil, a fuller or swage for controlled shaping, or a jig and gauge that make repeated work more accurate. Before any metal is heated, a competent worker plans the function, dimensions, material, process sequence, risk controls, inspection points and resources.

In the current England Blacksmith Level 3 apprenticeship standard, blacksmiths are expected to interpret specifications and drawings, plan work, prepare a safe working environment, select materials and equipment, and manufacture or maintain hand tools including tongs, punches, chisels, hammers, anvil tools and jigs. Planning is therefore not paperwork added after the craft: it is part of the craft.

The annotated anvil image helps you use common practitioner terms such as face, horn, step, hardy hole and pritchel hole. Source and licence information: Wikimedia Commons — Anvil, labelled en.svg.

A craft blacksmith working at an anvil and portable forge in a UK museum collection. Use the image to identify the work zone, tool reach, hot-material route and possible bystander hazards. Source and licence information: Wikimedia Commons — Craft blacksmiths at Anson 6007.JPG.

United Kingdom media context: This video looks around a British Artist Blacksmiths Association exhibition. Use it to observe the range of artistic ironwork and infer how specialised tooling, templates and jigs may support repeatable craft production. It is inspiration, not a safety instruction or qualification standard.

Learning Outcomes

By the end of this module, you should be able to explain the planning logic for making or maintaining common forging tools and aids; interpret a simple job brief, sketch or sample; distinguish critical dimensions from non-critical features; select known and suitable stock by reference to the job specification; calculate and record a reasonable stock allowance using approved workshop data or a trial; choose an appropriate supervised process sequence; identify key hazards and controls before work begins; define quality checks and hold points; prepare a clear job sheet; and justify sustainable choices without reducing safety or service life.

UK Authority Check and Scope

Occupational Safety: England within Great Britain

The following framework is relevant to supervised blacksmithing work in England. This summary is educational and is not legal advice.

Area	What it means for planning and preparation	Official source
General risk management	Under the Management of Health and Safety at Work Regulations 1999, employers must identify hazards, evaluate risk and eliminate or control risk. Your job plan should therefore identify who may be harmed, existing controls, further controls and the person responsible.	HSE: Managing risks and risk assessment at work
Work equipment	PUWER requires work equipment to be suitable, maintained, inspected where necessary and used by people who have adequate information, instruction and training. Planning must include guards, isolation, condition checks and authorised users.	HSE: PUWER overview
Maintenance	Maintenance must be planned so that equipment can be maintained safely and unexpected start-up or release of energy is controlled.	HSE: Maintenance of work equipment
Hazardous substances	COSHH applies to relevant dusts, fumes, metalworking fluids, degreasers, coatings and other hazardous substances. The control hierarchy and safety-data information must be considered before the task.	HSE: COSHH and engineering workers
Welding fume	Where welding forms part of an approved tool-making or repair process, effective engineering controls are required and RPE may also be needed where engineering controls do not adequately control residual exposure.	HSE: Mild-steel welding-fume safety alert
Noise	The Control of Noise at Work Regulations 2005 use lower and upper exposure action values of 80 dB(A) and 85 dB(A), with an exposure limit value of 87 dB(A) after accounting for hearing protection. Hammering, grinding and powered forging can require a formal noise-control plan.	HSE: Noise Regulations
PPE	PPE selection follows risk assessment and the hierarchy of controls. The Personal Protective Equipment at Work Regulations 1992 were amended in 2022 to extend duties to limb b workers as defined by HSE.	HSE: PPE at work regulations from 6 April 2022
Fuels and flammable substances	DSEAR requires employers to assess and control risks from dangerous substances such as LPG and other flammable gases. Fuel storage, ignition sources, emergency arrangements and training belong in the work plan.	HSE: DSEAR
Manual handling	Hazardous manual handling should be avoided where reasonably practicable; unavoidable tasks are assessed and the risk reduced. Heavy stock, anvils, dies and tooling may require handling aids or a different work method.	HSE: Manual handling at work
Lifting equipment	If lifting equipment is used for heavy tooling or components, LOLER may apply in addition to PUWER. Lifting operations must be properly planned by a competent person, appropriately supervised and carried out safely.	HSE: LOLER overview

Important: PPE does not replace elimination, substitution, engineering controls or safe systems of work. The exact PPE for a forge task must be selected by the employer or competent person for the actual hazards, and it must fit the wearer.

Vocational Training: England

Skills England lists the Blacksmith apprenticeship standard as ST0378, Version 1.1, approved for delivery at Level 3 with a typical duration of 48 months. The occupational standard includes interpreting drawings and specifications, setting up for work, risk management, making and maintaining forge tools and jigs, testing and adjustment, and planning time and resources.

Official reference: Skills England — Blacksmith ST0378 v1.1.

This aiMOOC supports learning related to that occupational area, but completion of this module does not award the apprenticeship, a certificate, trade status or independent competence. Employer assessment, formal training and end-point assessment arrangements remain separate.

No claim is made that this England apprenticeship is automatically equivalent to blacksmithing qualifications in Ireland, the United States, Canada, Australia, New Zealand, South Africa or any other country.

Standards: United Kingdom

BSI is the United Kingdom's National Standards Body. Standards are not automatically laws, and whether a particular standard applies depends on the job, contract, product, customer requirement or other obligation. Always check the current BSI catalogue before relying on a standard number or edition.

For material identification, BSI lists BS EN 10027-1:2016, Designation systems for steels — Steel names as current and under review at the time of this module check. It provides a system for steel names. For hardness testing where a job specification requires a Rockwell test, BSI lists BS EN ISO 6508-1:2023, Metallic materials — Rockwell hardness test — Test method as current.

Official references: BSI — UK's National Standards Body, BSI — BS EN 10027-1:2016, BSI — BS EN ISO 6508-1:2023.

Core Concepts

Tool, Aid, Fixture, Jig and Gauge

In everyday forge practice, terminology can overlap, so the workplace drawing or job sheet should define the intended function.

Term	Typical meaning in a blacksmithing workshop	Planning question
Forging tool	A hand or anvil tool that directly acts on or holds the hot work, such as tongs, a punch, chisel, fuller, swage or hardy tool.	What load, contact geometry, temperature exposure and service life must it withstand?
Aid	A broad term for something that makes the work safer, faster, more repeatable or easier to check.	Does the aid locate, support, measure, guide or protect?
Jig	A purpose-made aid that locates or guides work so a feature can be repeated consistently.	What datum and stop surfaces control the result?
Fixture	A device that securely locates or supports work during an operation.	How is the work restrained without creating a pinch, ejection or access hazard?
Template	A shape reference for marking or checking a profile.	Which profile is critical and how will wear of the template be detected?
Gauge	A checking aid used to verify size, angle, gap, radius or another feature.	Is it a comparative check or a calibrated measurement?

Use this image to classify visible items as holding tools, striking tools, forming tools or aids. Source and licence information: Wikimedia Commons — BLACKSMITH TOOLS.jpg.

Functional Thinking Before Form

A professional tool plan starts with function rather than appearance. Ask what the tool must do, what stock it must hold or shape, what force path it experiences, where the operator's hands will be, how it will be inspected, and what failure would look like.

For tongs, practitioners commonly refer to the jaws or bits, boss, rivet or pivot and reins. The critical requirement is not merely that the tongs look symmetrical: the jaws must contact the intended work securely, the boss and pivot must move correctly, the reins must give suitable clearance, and the tool must be free from defects that could cause loss of control.

The photograph shows traditional blacksmith's tongs. Use it to identify jaws, pivot region and reins. The image is from North Macedonia and is used only to illustrate generic tool anatomy; it is not a comparison of UK law, qualifications or workshop rules. Source and licence information: Wikimedia Commons — Tongs - Macedonian blacksmithing craft.jpg.

Critical Dimensions and Datums

A critical dimension directly affects fit, function, interchangeability or safety. A non-critical dimension may allow wider variation without affecting the tool's purpose. On a jig, a stop position may be critical; on tongs, jaw fit and alignment are usually more important than decorative consistency in the reins.

Use a clear datum system. Mark which face, centreline, edge or hole is used as the reference. Record the units. Do not assume that a sketch is to scale.

A useful planning sequence is:

JOB BRIEF
   ↓
FUNCTION AND FAILURE MODES
   ↓
DRAWING / SAMPLE / DATUMS
   ↓
MATERIAL AND STOCK SIZE
   ↓
PROCESS SEQUENCE
   ↓
HAZARDS AND CONTROLS
   ↓
QUALITY HOLD POINTS
   ↓
SUPERVISOR AUTHORISATION
   ↓
PRODUCTION
   ↓
FINAL INSPECTION AND RECORD

Stock, Forging Allowance and Traceability

Stock is the starting material supplied as bar, plate or another section. Planning should record the material grade where known, the section, the required starting length or blank size, the source and any job-specific traceability requirement.

Forging allowance means additional material or dimensional provision needed so the final forged and finished part can meet the specification after deformation, trimming, scale loss or machining where applicable. Do not invent a generic percentage. Use the employer's approved data, a verified previous job, a controlled trial piece or a calculation accepted by the supervisor.

Known material matters. For a safety-critical striking or struck tool, do not assume that visually similar scrap is suitable. If grade or condition is unknown, quarantine it until the competent person decides whether it is suitable for a non-critical purpose, needs testing or must not be used.

Process Planning

A process plan describes the order in which the work will be produced and checked. For forging tools and aids it may include stock preparation, marking out, controlled hot forging, punching or drilling, fitting, grinding, heat treatment where specified, assembly, trial fitting and final inspection. The plan should identify which operations require separate authorisation, extraction, guarding, isolation, lifting equipment or specialist competence.

Plan the holding method before the work gets hot. A safe plan states how the workpiece is controlled at each stage and what tool replaces the first holding method when the geometry changes.

Tools, Materials and Resources

Resource group	Examples	Planning purpose
Measuring and marking	Steel rule, square, calipers, dividers, scriber, centre punch, angle gauge, radius gauge	Establish datums, dimensions, hole centres and inspection criteria.
Hand forging tools	Hand hammer, tongs, punches, drifts, chisels, fullers, swages, hardy tools	Produce or maintain forms under an approved supervised method.
Aids	Jigs, templates, go or no-go gauges, stops, bending forks, support blocks	Improve repeatability and reduce unnecessary handling or rework.
Workholding	Leg vice, bench vice, clamps or purpose-designed fixture where suitable	Hold cold work securely for the approved task while avoiding damage and pinch hazards.
Powered equipment	Pillar drill, grinder, power hammer, press or other workshop machinery	Use only where the process requires it and only by authorised, trained users under the workplace system.
Materials	Verified steel stock, specified rivet stock, replacement handles where appropriate, abrasives, lubricants and approved coatings	Match the job specification and service conditions.
Controls	Guards, local exhaust ventilation, screens, isolation arrangements, fire controls, handling aids, suitable PPE	Reduce risk before and during production.
Documentation	Job sheet, drawing, risk assessment, method statement where required, inspection record, maintenance log	Make the work traceable and reviewable.

A London-pattern anvil provides a useful reference for discussing the face, horn, step, hardy hole and pritchel hole when planning anvil tooling. Source and licence information: Wikimedia Commons — London pattern anvil.jpg.

Risk Controls Before Work Starts

Risk control begins during planning. Do not treat the PPE column as the first or only control.

Hazard	Typical exposure in this module's work	Planning controls to consider
Hot metal, scale and fire	Heating, moving and forging stock; hot tools that may look cold	Separate hot and cold zones, defined hot-metal route, suitable stands, housekeeping, fire arrangements, clear communication and competent supervision.
Impact and ejected particles	Hammering, chiselling, punching, drifting and testing	Correctly maintained tools, screens where required, exclusion of bystanders, suitable eye or face protection, sound striking surfaces and an approved test method.
Noise	Hammering, grinding, powered forging and compressed-air equipment	Reduce noise at source, separate noisy work, limit exposure, maintain equipment, apply hearing-protection zones and hearing protection where required by the assessment.
Dust and fume	Grinding, welding, cutting, coatings and some maintenance operations	Substitute or eliminate where possible, use suitable local exhaust ventilation or other engineering control, keep extraction maintained and use RPE only where the assessment requires it.
Machinery	Drilling, grinding, power hammer or press work	PUWER-compliant guarding, appropriate controls, isolation, authorised users, pre-use checks and task-specific training.
Flammable gas or fuel	LPG or other forge fuel	DSEAR assessment, approved storage and connections, ignition control, leak-management procedures and emergency arrangements.
Manual handling	Moving bar stock, jigs, anvils, dies or heavy tooling	Avoid unnecessary lifts, use handling aids, reduce carrying distance, plan team handling only where suitable and assess individual capability.
Entanglement	Rotating machinery and loose clothing, jewellery or hair	Follow the machinery-specific safe system, secure clothing and hair, and select hand protection only where it does not introduce an entanglement hazard.
Poor maintenance	Cracked, mushroomed, loose, worn or distorted tools	Quarantine defects, mark the tool out of service, record the fault, decide repair or scrap through a competent person and inspect before return to service.
Fatigue and poor access	Repetitive hammering, awkward reach, unsuitable work height	Plan work-rest pattern, use suitable working height and handling aids, rotate tasks where appropriate and stop when control or concentration is reduced.

United States media context: Black Bear Forge discusses general shop safety. Use the video as a prompt to identify hazards, not as UK legal guidance. US terminology and practice do not override HSE requirements, the employer's risk assessment or your supervisor's instructions.

Step-by-Step Demonstration: Planning a Pair of Tongs

This demonstration stops at the point of authorised production. It is deliberately focused on planning and preparation, not unsupervised hot forging.

Scenario: A supervised workshop needs a pair of tongs to hold a specified square bar used repeatedly for a class exercise.

Job brief: Write the function in one sentence: the tongs must securely hold the specified stock through the planned forge operations without forcing the learner into an unsafe grip or reach.
Reference sample: Examine an approved pair of tongs or drawing. Identify the jaws, boss, pivot and reins, and note what is critical to function.
Critical dimensions: Record the stock size to be held, jaw contact requirement, pivot location, required opening range and any specified overall limits. Mark the datum used for each measurement.
Material identification: Select only material approved by the workshop. Record grade or stock identity, section, source and condition. Do not substitute unknown scrap without approval.
Stock calculation: Estimate the blank requirement using the employer's proven allowance, a supervised calculation or a controlled trial. Record the assumption so it can be reviewed.
Process sequence: List the intended stages in a logical order such as stock preparation, jaw and boss formation, pivot preparation, assembly, adjustment and final inspection. Do not add an operation unless the workshop has an approved method for it.
Holding plan: State how the work is controlled at each stage and how the holding method changes as the geometry develops. Check that hands remain outside the planned impact and hot-metal zones.
Equipment and controls: List the approved forge, anvil, hand tools, any machine operations, extraction, guards, fire arrangements, handling aids and PPE required by the task assessment.
Quality hold points: Define checks before assembly, after the pivot is fitted and at final trial. Include alignment, smooth movement, jaw contact, safe clearance and defect inspection.
Supervisor release: Present the job sheet, drawing, risk controls and material choice to the competent supervisor. Do not heat the first blank until the plan is accepted.

A good plan is easy for another competent person to follow, question and audit.

United Kingdom media context: This practitioner video shows tong making for a blacksmithing school in Norwich. Watch for sequence, workholding changes and the relationship between jaw geometry and function. Observation does not replace supervised instruction.

United States media context: This Black Bear Forge demonstration introduces tong making from flat stock. Use it to compare the filmed sequence with your written plan. Do not copy heat, striking or handling methods without approval in your UK workplace.

United States media context: Part two shows jaw shaping, assembly and adjustment. Focus on inspection and fit decisions rather than treating the video as permission to perform the work.

Planning Other Forging Tools and Aids

Punches and Drifts

A punch creates or starts a hole; a drift sizes, shapes or finishes it. Planning must identify the finished hole shape, taper or clearance where specified, tool material, working-end geometry, handle or holding method, heat-treatment requirement if any, and inspection criteria. A cracked, bent or mushroomed punch is not simply a cosmetic issue: quarantine it and follow the workshop's repair or disposal procedure.

Chisels and Hot Sets

A chisel or hot set must have the correct cutting geometry for its intended task and material. The plan should state whether the tool is handheld or handled, who will strike it, how the work is supported, and how the cutting edge and struck end are inspected. Do not improvise a struck tool from unidentified steel.

Fullers, Swages and Hardy Tools

Fullers and swages localise or control deformation; hardy tools fit the anvil's hardy hole. The plan must consider the working profile, shank fit, seating, clearance, direction of force and safe removal. A hardy shank should be made to the actual anvil and workplace specification rather than copied from a nominal size.

United States media context: This video demonstrates forging a hardy tool. Use it for process observation only. Any production in England must follow the local anvil dimensions, material specification, risk assessment and supervised method.

Jigs, Templates and Gauges

A jig should make the correct action easier and the wrong action harder. Define the datum, stops, clamping or location method, access, release path and wear surfaces. A gauge must clearly show what is acceptable. If a gauge can be mistaken for another size, mark it permanently.

For repeated artistic work, a template can preserve the intended rhythm or profile without eliminating handcraft. A well-planned template records the feature that matters while leaving non-critical surface character to the smith.

Maintenance Planning

Maintenance begins with inspection and defect reporting rather than with a grinder.

Condition found	Immediate planning response	Possible authorised outcome
Loose tong pivot	Remove from service if control is affected; record the defect and inspect boss, rivet and alignment.	Adjust, replace the pivot, repair or scrap according to the approved method.
Mushroomed struck end	Quarantine the tool and inspect for cracking or deformation.	Dress or remake only by an authorised competent person; scrap if integrity is doubtful.
Cracked tool	Mark out of service and prevent further use.	Competent assessment; commonly repair is restricted or the tool is scrapped depending on design, material and crack location.
Worn jig stop	Compare with drawing or master; measure the resulting error.	Replace or rebuild the stop and re-verify the jig.
Distorted tong jaws	Check intended stock, alignment and pivot condition.	Re-adjust under an approved method or remake if serviceability cannot be restored.
Damaged handle	Remove from service where the handle affects control.	Replace with the specified handle and fitting method before return to service.

HSE's PUWER guidance requires work equipment to be maintained in a safe condition, and maintenance activities themselves must be planned safely. Keep maintenance records where the workplace system requires them.

Common Errors and How to Prevent Them

Common error	Why it matters	Better planning practice
Starting from appearance rather than function	A visually neat tool may still grip poorly or misalign.	Write the function and critical checks before drawing the shape.
Using an unknown material	Heat treatment, toughness and failure mode become unpredictable.	Use verified stock or obtain competent approval for the intended use.
Confusing finished size with starting stock	The blank may be too short, too heavy or wasteful.	Record a justified forging allowance and review after the first controlled trial.
No holding plan	A safe first stage can become unsafe after the section changes.	Plan how the work will be held at every stage.
Ignoring jaw contact on tongs	Point or edge contact can reduce control.	Define the intended contact pattern for the actual stock.
Treating a jig as self-checking	Stops and holes wear and can reproduce the same error repeatedly.	Define inspection frequency and a master reference.
Planning grinding as the default correction	Grinding can create dust, noise, heat and loss of section.	Forge or machine to near-net shape where appropriate and use grinding only when specified and controlled.
Omitting inspection hold points	A defect can become expensive or unsafe to correct later.	Check before irreversible operations and before return to service.
Over-relying on PPE	PPE does not remove the hazard.	Apply the hierarchy of control and use PPE for residual risk.
Copying an online video without local review	Material, equipment, law and terminology may differ.	Treat video as observation; obtain workplace approval for the actual method.

Quality Criteria

A forging tool or aid is ready for service only when it meets the applicable job specification and has passed the workplace inspection.

Quality area	Evidence to look for
Function	The tool performs the intended holding, forming, guiding or checking task.
Fit	Tongs contact the intended stock securely; hardy tools or jigs fit their actual mating feature without unsafe looseness, wedging or interference.
Alignment	Jaws, pivots, guides, stops and working faces align as specified.
Dimensions	Critical dimensions meet the drawing, sample or approved tolerance.
Surface integrity	No unacceptable cracks, laps, sharp burrs, heavy scale pockets or other defects that compromise use.
Transitions	Changes of section are appropriate to the design and do not introduce avoidable stress concentrations.
Movement	Moving parts operate smoothly through the required range without binding.
Struck and working ends	Ends are in serviceable condition and meet the workplace geometry and material requirement.
Heat treatment	Where specified, treatment and verification follow the approved material procedure; hardness is not guessed from colour or spark appearance.
Identification	Tool size, owner, job or material identity is marked where the workshop system requires it.
Documentation	Job sheet, material identity, inspection findings and maintenance status are complete.

The workpiece and anvil image is useful for discussing work position, line of force and visual inspection. Source and licence information: Wikimedia Commons — Blacksmith at work02 less contrast.jpg.

Sustainability and Resource Efficiency

Sustainable blacksmithing does not mean extending the life of an unsafe tool. Safety and integrity come first. Within that boundary, good planning can reduce waste and energy use.

Use verified offcuts where their grade, condition and size suit a non-critical or approved job. Nest blanks to reduce scrap. Plan the sequence so repeated work can share setup time and, where appropriate, heating cycles. Maintain forges, extraction and powered equipment so they work efficiently. Repair jigs, tongs and fixtures when repair is safe and documented. Segregate recyclable steel, abrasive waste and hazardous waste according to the workplace system. Avoid unnecessary grinding by planning near-net forms. Record successful blank sizes so future jobs begin with evidence rather than excess stock.

The choice between solid fuel, gas, induction or other heating systems depends on workshop infrastructure, product needs, energy source, emissions controls, training and cost. This module does not present one fuel as universally superior.

This forge photograph was taken in Malta and illustrates the general relationship between fire, fuel and air. It is not UK installation or legal guidance. Source and licence information: Wikimedia Commons — Traditional Blacksmith Forge.jpg.

Inclusive Professional Practice

A professional forge plans for different bodies, communication needs and experience levels. Provide clear written and demonstrated instructions; use agreed hand signals where noise makes speech unreliable; select PPE in sizes and designs that fit the individual; use suitable work heights, handling aids and task rotation; and make reasonable adjustments through the employer's risk-assessment process.

Do not assign tasks on stereotypes about age, gender, strength or disability. Assign work according to competence, authorisation and the actual control measures. Learners may demonstrate planning knowledge through a written job sheet, annotated drawing, oral professional discussion, accessible digital document or other approved format, while practical evidence remains subject to the same safety and competence requirements.

Glossary

Term	Practitioner meaning in this module
Anvil face	Hardened working surface used for most forging operations.
Boss	Thickened central region of many blacksmith's tongs around the pivot.
Datum	Chosen reference point, line or surface from which dimensions are taken.
Drift	Tool used to size or shape a previously created hole.
Fixture	Device that locates or supports work during an operation.
Forging allowance	Planned extra material or dimensional provision that permits forging and finishing to the required final size.
Fuller	Tool with a rounded working profile used to localise deformation or create a groove or transition.
Gauge	Device used to check a dimension, shape, gap, angle or other feature.
Hardy hole	Square hole in many anvils used to locate hardy tooling.
Hardy tool	Anvil tool with a shank designed to fit the hardy hole.
Heat	In practitioner usage, one working cycle in which metal is heated for a controlled forging stage.
Jig	Purpose-made aid that guides or locates work to improve repeatability.
Jaw	Working end of tongs that contacts the stock; also called the bit in some shops.
Pritchel hole	Round hole in many anvils used for operations such as punching clearance.
Punch	Tool used to create or begin a hole or local indentation.
Reins	Long handles of blacksmith's tongs.
Stock	Starting material before it is made into the tool or component.
Swage	Tool with a shaped working surface used to form a matching or related profile.
Template	Physical shape reference used for marking or comparative checking.
Traceability	Ability to connect material, process and inspection information to the specific tool or job.

Reflection

Consider one tool in your training forge that is used frequently. What is its real function? Which features are critical to safe use? How is it identified? What signs would make you quarantine it? What information would you need before making a replacement? Which part of the current process creates the most waste, waiting or rework?

Then compare your answers with the workshop job sheet or supervisor's method. Any disagreement is a useful starting point for professional discussion rather than a reason to improvise.

Interactive Tasks

Quiz: Test Your Knowledge

What should happen before the first blank is heated for a new forging tool? (The work plan and controls should be reviewed and authorised) (!The final polish should be selected) (!The tool should be tested at full load) (!The material identity should be ignored)

Which item is most important when selecting steel for a safety-critical struck tool? (Known material identity and approved suitability) (!A similar colour to an old tool) (!The heaviest offcut available) (!The lowest purchase price)

What is the main purpose of a forging allowance? (To provide enough material for forging and finishing to final requirements) (!To replace the drawing tolerance) (!To increase the tool weight without reason) (!To avoid recording the stock size)

Which part of blacksmith tongs forms the long handles? (Reins) (!Boss) (!Jaw) (!Rivet)

What does PUWER require in relation to work equipment? (It must be suitable maintained and used by adequately trained people) (!It may be used without inspection if it is old) (!Only powered machinery is covered) (!Maintenance can be done without planning)

What is the correct response to a cracked struck tool found during inspection? (Quarantine it and follow the competent repair or disposal procedure) (!Keep using it until the crack grows) (!Hide the crack with paint) (!Strike it harder to test it)

Which statement best describes PPE in risk control? (It protects against residual risk after higher-level controls are considered) (!It removes the hazard completely) (!It replaces machine guards) (!It makes risk assessment unnecessary)

What is a datum on a forging-tool drawing? (A defined reference used for measurement and location) (!A decorative surface finish) (!A type of forge fuel) (!A heat-treatment colour)

Why should a jig have defined inspection points? (Wear can reproduce the same error in every part) (!A jig never changes dimension) (!Inspection is only needed after failure) (!Jigs are exempt from quality control)

What does completing this aiMOOC automatically provide? (No trade certification or independent competence) (!A Level 3 apprenticeship certificate) (!Permission to operate every forge) (!Automatic qualification equivalence abroad)

Memory Game

Datum	Reference used for measurement and location
Reins	Long handles of blacksmith tongs
Drift	Tool used to size or shape a hole
Jig	Aid that locates or guides repeated work
Traceability	Link between material process and inspection records
Fuller	Tool used to localise deformation
Boss	Thickened tong region around the pivot

Drag and Drop

Match the correct terms.	Topic
Define the function and critical dimensions	Job brief and drawing
Confirm known grade and section	Material selection
List hazards controls and authorised equipment	Risk planning
Set checks before irreversible operations	Quality hold points
Record findings and obtain supervisor release	Production authorisation

...

Crossword Puzzle

Tongs	What holding tool has jaws a pivot and reins?
Fuller	What rounded forming tool localises deformation?
Swage	What shaped tool forms a matching profile?
Hardy	What anvil tool fits the square anvil hole?
Pritchel	What word names the round hole found in many anvils?
Allowance	What planning term means extra material provided for forging and finishing?

LearningApps

Cloze Text

A professional tool plan begins with the required

. The drawing should identify critical dimensions from a clear

. Material for a safety-critical tool should have known

. Extra stock planned for deformation and finishing is called a forging

. The holding method should be planned before the first

. Risk control should follow the control

. Damaged tools should be placed in

until a competent decision is made. A repeated-work aid that guides or locates work is a

. A defined inspection stage before the next operation is a quality

. Production begins only after the required workplace

.

Open-Ended Tasks

Easy

Tool anatomy sketch: Choose an approved cold forging tool from the training area and make an annotated sketch naming its functional regions, wear points and safe holding surfaces.
Job brief rewrite: Rewrite a vague tool request as a clear one-sentence function statement plus three critical requirements that a supervisor could review.
Hazard spotting photograph: With permission, photograph a cold and inactive work area and annotate potential trip, access, storage and tool-condition issues without operating any equipment.
Material traceability card: Design a simple card that records stock grade, section, source, job number and intended use for a supervised tool-making task.

Standard

Tong planning sheet: Produce a complete pre-production plan for tongs to hold a specified stock section, including datums, critical dimensions, material identity, sequence, holding plan, controls and quality hold points.
Jig inspection project: Select an existing workshop jig with your supervisor, compare it with its drawing or master, document wear and propose an inspection interval based on use and consequence of error.
Blacksmith interview: Interview a practising blacksmith or vocational instructor about how they decide whether to repair, remake or retire a worn forging tool, then compare the answer with workplace maintenance records.
Waste map: Observe a supervised production session and map where offcuts, scale, grinding waste, waiting time and reheating occur, then suggest two changes that preserve quality and safety.

Advanced

Tool failure review: Analyse an instructor-provided retired or defective tool, identify plausible failure modes, separate evidence from assumptions and write a recommendation for inspection, repair restriction or scrapping.
Process comparison video: Create a short educational video comparing two approved ways of planning the same tool or jig, focusing on holding strategy, control measures, resource use and inspection rather than unsupervised forging instructions.
Production planning experiment: Under instructor control, compare two documented blank-size estimates using cold mock-ups, calculations or supervised trial data and evaluate material efficiency against final quality.
Expert review dossier: Assemble a professional dossier containing a drawing, material record, risk-control summary, process sequence, inspection plan, sustainability note and sign-off page for an experienced blacksmith and health-and-safety reviewer.

Learning Assessment

Planning rationale: Given a drawing for a tong or hardy tool, explain which features are safety-critical, which are quality-critical and which can vary, and justify your distinction.
Material decision: Compare verified new stock with an unidentified scrap offcut for a struck tool and explain why traceability changes the acceptable planning decision.
Risk-control transfer: A planned job changes from hand filing to powered grinding; identify which parts of the risk assessment, equipment check, exposure control and supervision plan must be reviewed.
Maintenance judgement: Given photographs and measurements of a worn jig and a loose pair of tongs, decide what should be quarantined, what additional evidence is needed and who should authorise return to service.
Quality planning: Design three hold points for a tool-making process and explain what defect each hold point is intended to catch before further work adds cost or risk.
Sustainability trade-off: Evaluate whether repairing a worn tool is more sustainable than remaking it when repair would require substantial grinding, welding or uncertain heat treatment, and defend a safety-first decision.

Evidence of Learning

Evidence type	What strong evidence looks like
Knowledge	Accurate use of practitioner terms; understanding of function, datums, allowance, material identity, risk hierarchy, PUWER-style equipment planning and quality hold points.
Skills	Clear interpretation of drawings and samples; systematic stock planning; hazard identification; process sequencing; inspection planning; professional communication and record keeping.
Products	Annotated drawing, job sheet, material traceability record, risk-control summary, jig or tool inspection sheet, sustainability note and expert-review dossier.
Professional behaviour	Stops when information is missing, asks for competent guidance, quarantines defective tools, respects authorisation limits and records changes rather than improvising.
Transfer	Can apply the same planning method to tongs, punches, drifts, chisels, fullers, swages, hardy tools, templates, gauges and jigs without assuming that one tool's dimensions or material suit another.
Reflection	Can explain what changed after supervisor feedback and how evidence improved the final planning decision.

Media and Open-Licence Notes

The Wikimedia Commons images in this module were selected because their exact file pages are verifiable and provide licence information. Check the file page if you reuse an image outside MOOCwiki. The external YouTube videos are embedded for observation and discussion; they are not presented as open-licensed course content unless the uploader separately states such a licence.

No Sofatutor content is used.

Media references:

Official Sources and Expert Review

The following sources were checked for this England-focused module on 1 September 2026. Official rules and workplace instructions take precedence if any summary here becomes outdated.

Expert-review checklist: A practising blacksmith or artist blacksmith should review the terminology and production realism; a competent health-and-safety person should review the workplace risk-control framing; an England apprenticeship or vocational-training specialist should review alignment with current ST0378 arrangements; and a quality or standards specialist should confirm any British Standard cited by a specific workplace project before learners rely on it.

OERs on the Topic

Useful open or freely accessible starting points include Blacksmith, Forging, Anvil, Tongs, Heat treatment, Tool steel, Risk assessment, Occupational safety and health and the HSE pages listed above. Wikipedia and Wikimedia Commons content should be reused according to the licence stated on the relevant page.