Ian Zimmerman, 20, a Northern Bedford County High School graduate and a science major at California University of Pennsylvania in Washington County, appeared on the reality show Nov. 2.

Traveling to the show for taping, Zimmerman, then 19, competed against three other bladesmiths during the episode, “Supersized: Hog Wild.”

Taking 12 pounds of steel, the contestants were to create what is known as a “hog splitter.”

Host of the show, Grady Powell, said contestants were tasked with making the largest blade ever asked of forgers in the first round.

Ian Zimmerman works on his entry for the episode, titled “Supersized: Hog Wild.” Courtesy photo

The final round of the episode had the two remaining contestants forge a 5-foot Japanese “great-sword.”

To create the sword, the contestants got to spend four days at their home forges completing the project for judges.

Zimmerman came out victorious, winning the $10,000 prize and the title of “Forged in Fire Champion.”

The other contestants couldn’t get over his age, Zimmerman said, noting he was the youngest on the episode.

“They’d ask during downtime to go and get a drink and when I told them I was 19, they laughed,” Zimmerman said.

A crew member from “Forged in Fire” films Ian Zimmerman as he works on his entry for the episode “Supersized: Hog Wild” at his home in Northern Bedford County. Courtesy photo

Zimmerman, who is rather new to forging — having picked it up during the pandemic — said he found the experience interesting. The other contestants were hobbyists just like him, he said.

“Just talking with them, it was interesting learning that none of them were forging full time, this was just a hobby they enjoyed doing,” he said.

Zimmerman took on the competition with the permission of his professors and his athletic coaches, as the show was filmed during his first year of college.

“I initially asked my track coach and professors if this was something I could do, being that I was participating in the current running season and I had a full class schedule,” he said.

They were very supportive of the endeavor, with one coach even suggesting he go home early to prepare.

Ian Zimmerman, seen with his winning sword from “Forged in Fire,” learned the process of forging metal during 2020, when school was closed due to the COVID-19 pandemic. Courtesy photo

But that wasn’t necessary, he said.

“There’s no real practice. Forging is more muscle memory,” Zimmerman said. “And it can be very hard on the body.”

Zimmerman’s parents Angie and Ricky Zimmerman said they were surprised and excited for Ian’s opportunity to be on the reality show.

It was “unlike anything anyone around us had ever experienced,” Angie Zimmerman said, adding that she knew Ian would do great things.

“He’s a blessed kid who’s always excelled in everything he’s done, not just with hobbies but with his cross country and track as well,” she said.

Ian Zimmerman, seen working on the sword he created for the show, enlisted the help of family friend and blacksmith Jake Hall to learn how to forge blades. “He’s such an artistic kid and had no trouble learning,” Hall said. Courtesy photo

Learning the craft

Forging is the process of heating up metal, changing its structure and creating something new, Zimmerman said.

It’s a process he learned in 2020, when school was closed due to the COVID-19 pandemic.

He was looking for something to do to keep busy and, with the help of family friend and blacksmith Jake Hall, started his journey as a bladesmith.

“He was crazy about it when he started,” Hall said of Zimmerman’s zest for forging. “He would come over to the house almost every weekend and talk about heat treating and other techniques.”

Hall set Zimmerman up with an anvil and various equipment, taught him the basics and said he knew the teen would excel.

“He’s such an artistic kid and had no trouble learning,” Hall said. “He got the basics of the process down in no time.”

Forging is a hot process, with temperatures around the forge reaching 150 degrees on summer days.

“For the metal to be easy to work with, I’d have to heat it up in a 2,000 degree forge,” Zimmerman said. “I’d take lots of water breaks and always wear the proper safety equipment.”

As he became more comfortable in forging, Zimmerman looked to movies and online videos for inspiration on new ways to forge and new designs.

“I watched a lot of YouTube,” he said. “There were a lot of videos and creators on there doing things I hadn’t even thought of. It made me want to try them myself.”

He’s created a variety of pieces, including knives, swords and other blades and has kept family and friends updated on his projects via his Facebook page, Ian Z Knives.

Forging to remain a hobby

Asked where the interest in forging came from, Ricky Zimmerman said his son was always eager to learn, even at a young age.

“Growing up, Ian loved props, especially the ones from movies and video games that he liked,” he said.

Growing up, the younger Zimmerman would help his carpenter dad with projects.

“When I’d be working on something, Ian would be there to participate,” Ricky Zimmerman said. “I saw he wanted to try to make a sword and I suggested we try it out with wood first.”

The duo also watched previous seasons of “Forged in Fire” together.

“We could be watching a show like ‘American Ninja Warrior’ and Ian would go on about how he wanted to do that,” the elder Zimmerman said. “He felt that same way when he watched ‘Forged in Fire,’ and if he was going to do something, he meant it.”

Zimmerman won the “Forged in Fire” contest months ago — the show was filmed in Connecticut over a several month period — though he couldn’t tell everyone until after the episodes aired.

Since the filming, he’s been back at college working toward finishing his science degree and completing the track and field season.

He plans to use his forging skills on a new venture — jewelry making.

“Skills I’ve learned from forging are used at a small scale while making jewelry,” he said.

Being a bladesmith will remain a hobby, but “with jewelry making, I’m able to make a steady income for myself and my future.”

He also has plans to marry his fiancee, Nicole, very soon.

Ricky Zimmerman admires his son’s skills, but also his close relationship with his beliefs.

“As his parents, we know that Ian keeps God close to his heart. As long as the things he’s going after doesn’t cost him his beliefs, he’ll be able to do nothing but succeed in life. He’s a great kid. … Well, he’s a man now.”