- Joined
- Apr 3, 2026
- Messages
- 7
Hello, long time lurker of the forum.
I've spent quite a bit of time searching online, including old Bladeforums threads, and I've been surprised by how little information I can find about safely operating a hydraulic forging press.
There are plenty of videos showing presses in action and how to use them and many discussions about building them, but very few resources focused specifically on safety.
A little ago, I got excited and jumped on an opportunity to purchase a used 12-ton Coal Ironworks press from a retiring smith without doing all the research I should have beforehand. Since then, Google, Reddit, and various internet articles have painted an alarming picture: hydraulic injection injuries, failed hoses, hot projectiles, shop fires, crushed and amputated fingers, and more.
At this point, I've pretty well scared myself out of using the press, and I'm hoping some experienced press users can provide practical advice - not just for me, but for other smiths who may be searching for the same information.
One area I've already looked into, and think I have a good strategy for, is protecting myself from the hydraulic system. Based on advice from Reddit and other sources, my current plan includes regularly inspecting hoses and fittings, checking for leaks before use, protecting hoses from hot scale and slag, and using sleeves or guards where appropriate to help mitigate pinhole leak risks or blowouts. Those precautions have helped ease my concerns about the hydraulic components.
However, another topic that came up repeatedly was the possibility of hot projectiles from cracked workpieces or damaged dies, material being ejected at high velocity during pressing operations, and tongs slipping or being pinched and causing hand injuries.
I can see ways to reduce tong-related risks by using appropriately sized tongs with longer narrower reins that I can't get my fingers in-between and maintaining good control of the work.
The projectile risk is what I'm now struggling to wrap my head around.
The advice I've encountered so far seems to be to avoid loose tooling, keep dies and tooling in good condition, forge at high temperatures - never below a dull red, and pay close attention to workpiece and die alignment.
But, I'd love to hear from people with real-world experience.
For those of you who regularly use hydraulic forging presses some general questions:
I know there are at least a few smiths that consider hydraulic presses to be an unacceptably risky tool for their shop and instead opt for a power hammer but I'm not entirely sure why.
I'm fully aware that every piece of shop equipment carries significant risk. I'm comfortable with all my other shop equipment: Induction forge, 2x72 belt grinder, heat treating oven, arc welder, drill press, angle grinder, various powered saws, but this hydraulic press is giving me pause.
Maybe a hydraulic press simply isn't the right tool for someone who can't get comfortable around it.
That said, I'd really appreciate hearing practical first hand experience from those of you who know what you're doing.
Hopefully this thread can also become a useful resource for others in the future.
Thanks in advance for any advice!
I've spent quite a bit of time searching online, including old Bladeforums threads, and I've been surprised by how little information I can find about safely operating a hydraulic forging press.
There are plenty of videos showing presses in action and how to use them and many discussions about building them, but very few resources focused specifically on safety.
A little ago, I got excited and jumped on an opportunity to purchase a used 12-ton Coal Ironworks press from a retiring smith without doing all the research I should have beforehand. Since then, Google, Reddit, and various internet articles have painted an alarming picture: hydraulic injection injuries, failed hoses, hot projectiles, shop fires, crushed and amputated fingers, and more.
At this point, I've pretty well scared myself out of using the press, and I'm hoping some experienced press users can provide practical advice - not just for me, but for other smiths who may be searching for the same information.
One area I've already looked into, and think I have a good strategy for, is protecting myself from the hydraulic system. Based on advice from Reddit and other sources, my current plan includes regularly inspecting hoses and fittings, checking for leaks before use, protecting hoses from hot scale and slag, and using sleeves or guards where appropriate to help mitigate pinhole leak risks or blowouts. Those precautions have helped ease my concerns about the hydraulic components.
However, another topic that came up repeatedly was the possibility of hot projectiles from cracked workpieces or damaged dies, material being ejected at high velocity during pressing operations, and tongs slipping or being pinched and causing hand injuries.
I can see ways to reduce tong-related risks by using appropriately sized tongs with longer narrower reins that I can't get my fingers in-between and maintaining good control of the work.
The projectile risk is what I'm now struggling to wrap my head around.
The advice I've encountered so far seems to be to avoid loose tooling, keep dies and tooling in good condition, forge at high temperatures - never below a dull red, and pay close attention to workpiece and die alignment.
But, I'd love to hear from people with real-world experience.
For those of you who regularly use hydraulic forging presses some general questions:
- What specific practices do you follow to stay safe?
- Do you use any kind of blast shield, metal mesh curtain, or physical barrier to protect your body from a projectile just in case? If not, why not?
- Have you ever accidentally created a projectile while forging?
- Have you personally been injured, or known someone who was injured, while operating a forging press?
- In your opinions, how common is material ejection for presses in actual practice?
- If you were initially nervous about operating a press, how did you become comfortable with it?
- Any other practical advise for using hydraulic presses that you think would be helpful for people interested in using a press?
I know there are at least a few smiths that consider hydraulic presses to be an unacceptably risky tool for their shop and instead opt for a power hammer but I'm not entirely sure why.
I'm fully aware that every piece of shop equipment carries significant risk. I'm comfortable with all my other shop equipment: Induction forge, 2x72 belt grinder, heat treating oven, arc welder, drill press, angle grinder, various powered saws, but this hydraulic press is giving me pause.
Maybe a hydraulic press simply isn't the right tool for someone who can't get comfortable around it.
That said, I'd really appreciate hearing practical first hand experience from those of you who know what you're doing.
Hopefully this thread can also become a useful resource for others in the future.
Thanks in advance for any advice!