Over 2400 years ago, the art of forging Damascus knives as we know it today began with the Wootz technology from India. Wootz was a process by which iron was processed in a charcoal fired bellows to form a billet, or block of steel, with very little impurities. The technology of forming Wootz material into a layered steel was later perfected in the Middle East around 400 A.D. Early Crusaders from Europe first came in contact with the knives and swords made by this layer process in the trading city of Damascus and named the unique material after the city.
The Damascus technology is centered around using different metals heated in a forge, until hot enough to be hammered together into a single piece of material; this is also known as forge welding. Typically a hard high carbon steel material was coupled with a lower carbon steel material to give the blade both durability and flexibility once forge welded together. This welding process was repeated multiple times to fashion the layers in a large piece of material with the number of layers varying from a few to thousands. The only problem ancient smiths had with this layering process was that it was hard to control by hand, and blades would break apart at their forge welds if not properly done.