Narrator: This is a handmade iron kettle.
For centuries, artisans have made kettles
by pouring molten iron
through a small opening in molds like this.
Once the iron hardens,
they continue the tedious work
of hammering the kettle free.
It's only used to boil water,
but that doesn't make it cheap.
You can buy a mass-produced kettle for $20,
but a handmade iron kettle can cost over $300.
So, who makes these kettles,
and why are they so expensive?
This is Iwate Prefecture in Japan.
Iron kettles have been made here for hundreds of years.
Each one starts with a sketch.
Nobuho Miya runs Kamasada,
a workshop founded by his grandfather.
Narrator: Designing a new kettle
takes him two to three years.
Narrator: At this workshop,
every single kettle is made by hand.
But before you start melting iron, you need a mold.
The mold is made from three parts
that form a gap where the iron is poured in.
Narrator: The core is destroyed with each use,
but the outer molds are reused two to three times,
depending on the design of the kettle.
Narrator: According to Nobuho,
around 70% of the work is making the mold.
This process also creates
the most recognizable aspect of the design,
this bumpy pattern called arare.
This mold has around 2,000 dots, all placed by hand.
Narrator: Artisans coat the core with charcoal dust
to make it easier to separate from the iron.
Then Shotaro delicately places it inside the outer mold.
But he won't know if something went wrong
until the iron has cooled.
There's a lot of anticipation waiting for the iron to melt.
Shotaro has to mentally prepare for the pour,
a dangerous and physically demanding task.
A mistake here could ruin the kettle,
so experience and confidence are essential.
Once the iron cools,
Shotaro finally sees the result of his hard work.
Narrator: Traditional iron kettles like this one
don't have any enamel coating inside.
Instead, artisans heat the kettle
to 900 degrees Celsius on a bed of charcoal.
This creates an oxidized layer, which helps prevent rust.
Without an enamel coating,
the iron subtly changes the taste of boiled water.
But this kettle isn't done yet.
The final stage is one of the most skill-intensive steps.
Nobuho heats up the kettle and brushes on lacquer,
coating and coloring the outside.
Narrator: Most kettles from Kamasada cost $300 to $400,
but prices can be as high as $2,000.
Despite the high price, customers appreciate
the slow-paced nature of these kettles.
The design is considered wabi-sabi,
which is difficult to translate literally
but refers to the concept of appreciating imperfection
and practicing mindfulness.
Narrator: Iron kettles were common in Japan
in the 17th and 18th centuries,
when they were used in tea ceremonies.
But they struggled to compete with convenient
mass-produced options after World War II.
In recent years, interest in their aesthetic qualities
has reignited demand,
but that demand has brought on many knockoffs
that can be bought for a fraction of the price.
These kettles imitate the arare pattern
but usually aren't made in Japan.
They also have an enameled interior
instead of the bare iron used in the traditional version.
But the original uncoated interior
is actually one of the main selling points.
Customers say they like the taste
of water boiled in these kettles.
And some also value the small amount
of iron content it adds to their water.
Narrator: Despite an increase in popularity,
Nobuho says that demand for this type of kettle
isn't enough to sustain the business on its own.
Narrator: Shotaro, Nobuho's son,
has trained in making iron kettles
and plans on taking over the business
to continue this centuries-old craft.