Matt Coffey Design's custom metalwork process has six stages — discovery call, on-site consultation, sketching, material selection, forging and fabrication, and installation — typically spanning 6 to 18 weeks. Every commission is bespoke and quoted per project after a discovery call and site visit.

The Process.
From conversation to forged-in-place.
Discovery Call
Every project starts with a conversation. We discuss the scope, the function, the aesthetic intent, and the rough budget parameters.
I will tell you immediately if I am the right blacksmith for the job. If we are aligned, we move to the site visit.

On-Site Consultation
I do not build hypothetical metalwork. I need to see the space. I take exact measurements, evaluate structural tie-in points, and assess how light will interact with the finish.
For heavy installations, we also discuss logistics, access, and floor load capacities.

Concept & Sketch
I take the measurements back to the forge and draft the piece. You will receive a scaled drawing showing exactly how the design elements interact.
This is where we finalize the scrollwork, the proportions, and the joinery methods. It's the last stage before raw material is ordered.

Material & Finish Selection
You will select the exact texture and finish. A raw hammered steel looks entirely different from a brushed bronze or an oil-rubbed patina.
I will provide physical strike-offs (sample plates) if the finish is custom, so you can see how it reacts to the light in your chosen space.

Forging & Fabrication
The fire gets lit. Raw stock is cut, heated to 2,000 degrees, and manipulated at the anvil. This is the longest phase of the project.
I do not rush the fire. The metal dictates the pace. I will send progress photos from the shop so you can see your piece coming to life.

Delivery & Installation
For local projects, I personally deliver and mount the work. The installation must be as flawless as the fabrication to ensure absolute structural integrity.
For out-of-state commissions, the piece is custom-crated and shipped via freight with detailed mounting schematics.
Want to see more of our work? Explore the gallery

Inside the Forge.
Raw process, real fire, no filters. Follow along as each piece takes shape.

Sparks at 2,000°F — shaping a custom fireplace surround at the anvil.

Hot-riveted structural framing — traditional joinery for a barn conversion.

Forming a copper range hood — hand-planished one panel at a time.

The workshop — anvils, power hammer, and 25 years of tooling.

Pattern work — hand-cut decorative steel sheet before patina.

Vault door assembly — 600 lbs of steel coming together piece by piece.

Sleeping Bear panels — applying chemical patina for natural aging.

Plasma cutting The Oaks sign — raw steel before the rust takes hold.
What to prepare for our first call
- Rough dimensions of the space (height, width, or linear run).
- Images of the current installation area.
- 2-3 inspiration photos or rough sketches of what you want.
- Your timeline constraints, if any.
- A general idea of your finish preference (e.g., dark, light, rustic, polished).
