How does Rocky Hill Forge make its pans?

We start with a flat disc of copper, the diameter of which is carefully sized to match the desired cooking surface, plus double the height of the walls. The thickness of the copper is tailored to the pan's intended use. For our crepe pans, we use 1.5mm copper, a perfect balance between the ultra-thin 1.3mm (16 gauge) spun pans and the heftier 2mm+ models. This thickness ensures quick, even heating, while keeping the pan light enough for easy maneuverability. For our larger pans, we use 2.3mm copper—a robust workhorse material. While still heating relatively quickly, these pans retain heat longer, making them ideal for tasks requiring consistent temperature control.

All of our frying pans feature hand-forged stainless steel handles (for more details, see our blog post here).

The shaping of our pans is done using both wooden and metal forms that guide the curvature of the walls. We begin at the outer edge, hammering in concentric circles to gradually raise the walls to the desired height. Once the walls are shaped, we then turn our attention to the base, ensuring it remains flat while also introducing a subtle texture that enhances the non-stick qualities of the tin lining. 

The rivets used in our pans are crafted from 5mm copper, ensuring a secure and durable connection between the handle and the pan body. Unlike many lower-quality copper pans, which often feature large rivet heads but thin shanks that can weaken over time, our 5mm shanks provide a solid, stable attachment. This robust design not only ensures long-lasting strength but also allows for tightening if needed, maintaining the integrity of the connection throughout the life of the pan.

Finally, the lining of all our copper pans is applied by hand with tin, creating a beautifully non-stick surface that improves with use.