Process

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.

Metal fabrication in progress

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.

What you'll receive:
A verbal go/no-go and a ballpark estimate.
Typical Timeline:
1 - 2 Days
Discovery Call
Initial sketches and project planning during the discovery phase

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.

What you'll receive:
Exact dimensional capture and structural assessment.
Typical Timeline:
1 Week
On-Site Consultation
On-site measurement and structural evaluation of the installation area

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.

What you'll receive:
Scaled formal sketches and a firm fixed-price quote.
Typical Timeline:
1 - 2 Weeks
Concept & Sketch
Detailed sketches and technical drawings on the drafting table

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.

What you'll receive:
Final material lock and deposit invoice.
Typical Timeline:
1 Week
Material & Finish Selection
Metal sample plates showing various finishes and textures

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.

What you'll receive:
Progress photos and heavy hammering.
Typical Timeline:
4 - 12 Weeks
Forging & Fabrication
The forge at work—heated steel being shaped at the anvil

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

What you'll receive:
Final installed piece and care instructions.
Typical Timeline:
1 Week
Delivery & Installation
Careful installation and mounting of the finished piece

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).
Download printable checklist (PDF)
Book a Discovery Call