WSU Students Forge Ancient Greek Sword for Competition

The handcrafted xiphos sword will be showcased at the TMS Bladesmithing Competition next month.

Published on Mar. 2, 2026

Got story updates? Submit your updates here. ›

A team of Washington State University students has designed and forged an ancient Greek xiphos sword to compete in the upcoming Minerals, Metals & Materials Society (TMS) Bladesmithing Competition. The three-month project allowed the interdisciplinary team to apply materials science principles in a hands-on manufacturing environment, using advanced microscopy techniques to examine the metal's structure and gain insights into traditional blacksmithing processes.

Why it matters

The TMS Bladesmithing Competition brings together student teams from around the world to showcase their skills in designing and producing blades using traditional techniques. This project demonstrates how materials science can inspire and engage students across academic disciplines, fostering interdisciplinary collaboration and a deep interest in manufacturing processes.

The details

The WSU Material Advantage Club designed and forged the xiphos, a short double-edged sword widely used in ancient Greece, using 5160 spring steel. The material choice presented technical challenges that required rigorous problem-solving and adherence to safety protocols. The team used advanced microscopy techniques to create detailed color-coded maps showing the arrangement of metal crystals, helping them understand the blade's strength and flexibility.

  • The TMS 2026 155th Annual Meeting & Exhibition is scheduled for March 15–19 in San Diego.
  • The Bladesmithing Competition is held every other year during the TMS annual meeting.

The players

WSU Material Advantage Club

A student organization at Washington State University that focuses on materials science and engineering.

Alexander Overtoom

Associate Professor of History at Washington State University, an expert in medieval warfare.

Morgan Chapman

Team captain of the WSU Material Advantage Club project.

Amber Replogle

President of the WSU Material Advantage Club.

Mark Mills

Member of the WSU Material Advantage Club who will represent the team at the TMS 2026 Annual Meeting.

Got photos? Submit your photos here. ›

What they’re saying

“We learned a great deal about the crystal structure of metals and the forging processes involved in creating a blade of this size.”

— Morgan Chapman, Team captain (dailyfly.com)

“This interdisciplinary collaboration demonstrates that a deep interest in material structures and manufacturing processes is not limited to those formally trained in materials science but can inspire and engage students across the academic spectrum.”

— Amber Replogle, President, WSU Material Advantage Club (dailyfly.com)

“It was incredibly intense and stressful, but also one of the most rewarding experiences I've ever had. I'm incredibly proud of the team and grateful to our professors who were always there to offer guidance. It truly feels like we achieved the impossible.”

— Amber Replogle, President, WSU Material Advantage Club (dailyfly.com)

What’s next

Replogle and Mills will represent WSU at the TMS 2026 155th Annual Meeting & Exhibition, scheduled for March 15–19 in San Diego, where they will showcase the handcrafted xiphos sword.

The takeaway

This project demonstrates how materials science can inspire and engage students across academic disciplines, fostering interdisciplinary collaboration and a deep interest in traditional manufacturing processes. The WSU team's success in designing and forging an ancient Greek sword highlights the value of hands-on, problem-solving experiences in materials science education.