Monolithic Sword

If the the whole sword, blade and grip, is forged from a single piece of smelt,

$n=512$

$l_s=0.795\,m$

and the number of folds the smelt is subjected to,

$n_b=9$

If you are on the right path, the smelt first seems sticky and will stick to the hammer as you rise the hammer for the next strike to elongate the smelt.