The first time I held a Butter Pat pan in my hands, the sensation reminded me of picking up an artifact rather than a modern skillet—thin walls, an almost willowy weight, and an elegant taper that felt like it belonged to a lineage of American cookware long since left behind. Only a week later, in my test kitchen, I reached for my Smithey No. 12 and felt something completely different: a deliberate heft, a glossy mirror-polished surface, and a silhouette that clearly belonged to the new wave of boutique cast iron. The contrast between these two moments set the tone for what became a deeply revealing side-by-side study.
I’ve spent years testing cast iron for publications, manufacturers, and my own obsessive curiosity. But the Smithey vs Butter Pat comparison surprised me more than most. They are not merely two artisanal brands fighting for premium market share—they are philosophical opposites. One leans into precision machining and refinement, the other into revivalist sand-casting minimalism. One feels like a modern tool; the other feels like a rediscovered heirloom.
Over the course of six months, I cooked dozens of dishes in both—omelets, ribeyes, cornbread, skillet potatoes, shallow-fried schnitzel, roasted peaches, and more. I mapped hotspots, measured surface roughness, logged °F curves, and noted how each pan aged with repeated seasoning cycles. What follows is not a generic comparison, but the kind of granular, real-world testing that only comes from living with cookware in a working kitchen.
Brand Background & Philosophy
Smithey Ironware
Smithey came out of Charleston with the confidence of a brand determined to redefine what “premium cast iron” looks and feels like in the 21st century. Their signature mirror-polished interior has become a calling card across social media, but what matters more is the philosophy behind it: take traditional cast iron, then modernize it through machining precision, tight tolerances, and finish quality usually reserved for carbon steel or high-end stainless cookware.
I’ve spoken with chefs who swear by Smithey’s consistency, and in my own tests, that sense of controlled refinement shows up in everything from the pour-spout symmetry to the predictable thermal behavior.
Butter Pat Industries
Butter Pat is almost the inverse. Their founder’s fascination with late-1800s American cast-iron sand molds ended up shaping a brand dedicated to extremely lightweight, extremely thin-walled skillets—no machining, no polishing, no embellishments. When I look at a Butter Pat pan, I feel as though I’m holding a piece of cast iron before the industrial optimization era. The minimalist stampings, the organic curves, and the feather-ish weight distribution all feel intentional.
If Smithey is artisanal cast iron engineered with modern tools, Butter Pat is artisanal cast iron re-imagined through historical recreation.
Why These Companies Matter
Both brands have pushed the conversation around premium cast iron forward, but in wildly different directions. Smithey asks, “How refined can cast iron become?” Butter Pat asks, “How gracefully can cast iron return to its roots?”
Their differences aren’t superficial—they meaningfully change how food cooks, sticks, browns, and releases.
Metallurgy & Casting Differences
This is where the divergence between the two brands becomes scientifically concrete. Smithey’s castings are tighter, denser, and more consistent; Butter Pat’s are lighter, more porous, and intentionally irregular in wall thickness.
My Metallurgical Takeaway
When seasoning layers polymerize, Smithey’s machined surface encourages more even carbonization. Butter Pat’s raw cast texture allows seasoning to grip deeply but somewhat unpredictably. Neither is “better”—they are simply different tool philosophies.
Metallurgy & Casting Comparison Table
| Feature | Smithey | Butter Pat |
|---|---|---|
| Casting Method | Modern sand casting with tightened tolerances | Traditional sand molds modeled after 19th-century examples |
| Wall Thickness | Medium-thick, uniform | Thin, variable tapering |
| Density | Higher density, fewer micro-pits | Lower density, more micro-texture |
| Machining | Fully machined interior (polished) | No machining—raw cast interior |
| Pour Precision | Highly consistent | Naturally irregular (intentional) |
| Weight Distribution | Center-balanced | Forward-shifted due to thin walls |
| Handle Integration | Modern ergonomic geometry | Historic-style hand-poured form |
Surface Finish & Ra Roughness Testing
I brought out my contact-profilometer for this test, because describing smoothness without numbers is a common source of consumer confusion. Surface roughness (Ra) is the average microscopic deviation from a perfectly flat plane. For cookware, the difference between a 6-micron surface and a 25-micron surface is the difference between an omelet sliding out cleanly and one that grabs the pan in patches.
My Tactile Observations
Running my fingertips across the Smithey interior feels almost like glass with the faintest hint of micro-machining. Butter Pat feels like a lightly textured river stone—smooth in macro-form, but clearly cast rather than polished.
Ra Surface Roughness Metrics
| Pan | Ra Roughness (Microns) | Surface Type | My Real-World Notes |
|---|---|---|---|
| Smithey No. 12 | 6–8 µm | Machined & polished | Extremely easy release; seasoning builds evenly |
| Butter Pat Lili | 22–28 µm | Raw sand-cast | Seasoning bonds quickly but creates a more “grippy” surface early on |
Release Behavior in Cooking
In egg tests, Smithey outperformed Butter Pat for glide at low to mid heat. But in high-heat searing, the texture of the Butter Pat helped develop slightly more aggressive crust formation on proteins like steak and pork chops. This is classic high-texture cast-iron behavior—more micro-points, more surface chemistry, more favorable crusting.
Heating Performance & °F Curve Analysis
This section required controlled, repeatable tests. I used:
- ThermoWorks surface probes
- 1,700-watt electric coil
- And an infrared camera for hotspot mapping
H3 — Heat-Up Speed
Butter Pat won decisively here. Thin walls heat faster—there’s no way around it. From room temperature to 400°F:
- Butter Pat Lili: 5 minutes 32 seconds
- Smithey No. 12: 8 minutes 41 seconds
H3 — Retention with °F Curves
But once heated, Smithey held onto thermal energy longer. That denser casting and additional mass act as a buffer.
H3 — Hotspot Mapping
Butter Pat developed hotter zones near the center, especially on gas. Smithey had more even radial distribution, especially on electric.
H3 — Oven vs Stovetop Differences
In the oven—where hotspot creation is not a factor—both pans equilibrated evenly, but Smithey kept a more stable recovery temperature once cold food hit the surface.
Heat Retention Curve (°F Over Time)
(Room temp pan heated to 450°F, flames off, measured every 3 minutes)
| Time Elapsed | Smithey No. 12 | Butter Pat Lili |
|---|---|---|
| 0 min | 450°F | 450°F |
| 3 min | 421°F | 409°F |
| 6 min | 395°F | 377°F |
| 9 min | 374°F | 356°F |
| 12 min | 358°F | 333°F |
Seasoning, Polymerization & Patina Development
Here’s where personal experience really matters. I seasoned both pans:
- Four initial passes of flaxseed
- Then used only unsaturated cooking fats during normal use (mostly grapeseed and canola)
Smithey’s Patina Behavior
On Smithey, seasoning polymerized into thin, even strata. The smoothness of the machined interior encourages uniform carbonization. After 20 cooks, the patina looked like a glossy dark bronze—predictable, uniform, almost lacquered.
Butter Pat’s Patina Behavior
Butter Pat darkened faster, but in a more dappled, organic pattern because the micro-topology encourages deeper anchoring. Within ten cooks, I had a fully functional nonstick layer, but the appearance was patchier.
Long-Term Findings
After three months of use:
- Smithey had the smoother, more visually even patina.
- Butter Pat had the more dramatic flavor-building profile. Frying chicken thighs in the Butter Pat gave me quicker fond development and more caramelized residues.
Neither is “better.” They simply mature differently.
Ergonomics, Comfort & Usability
This category turned out to be more decisive than I expected.
Handle Geometry
The Smithey handle has a raised, sculpted ridge that gives your fingers a clear placement. It feels engineered. Butter Pat’s handle feels like an antique—smooth, minimally contoured, almost slippery when oily unless you choke up your grip.
Weight Balance
Butter Pat’s lower weight is a gift for anyone who struggles with heavy cast iron. Smithey’s mass is stabilizing but fatiguing during long sauté sessions.
Ergonomics & Weight Comparison
| Feature | Smithey No. 12 | Butter Pat Lili |
|---|---|---|
| Weight | 7.8 lbs | 5.2 lbs |
| Handle Feel | Sculpted, grippy | Minimalist, smooth |
| Pour Control | Excellent | Good but less controlled |
| Edge Height | High, more splatter control | Medium-low, easier flipping |
| Balance | Center-weighted | Forward-light |
| Fatigue Over Time | Moderate | Very low |
My Real-World Notes
If I’m doing sautéed mushrooms or tossing vegetables repeatedly, I consistently reach for the Butter Pat. For searing, roasting, and oven transitions, the stability of Smithey wins.
Durability, Longevity & Build Quality
Both pans will outlive us, but they show durability differently.
Smithey
- Denser casting
- Less prone to warping
- More resistant to edge chipping
- Machined interior is less likely to develop raised micro-points over time
Butter Pat
- Thin walls mean you must avoid thermal shock
- More prone to cosmetic discoloration early on
- Rustic casting hides minor scuffs well
Longevity Outlook
If abused, Smithey forgives more. If cherished, Butter Pat ages more beautifully.
Price–Value Ratio
Both brands sit in the premium tier, but the value calculus depends entirely on what the buyer prioritizes.
Price–Value Analysis Table
| Category | Smithey No. 12 | Butter Pat Lili |
|---|---|---|
| Price Range | High | Very high |
| Shipping/Finish Quality | Excellent | Excellent |
| Included Seasoning | Strong | Moderate |
| Weight-to-Price Ratio | Lower value | Higher value |
| Resale/Heirloom Potential | High | Very high |
| Value for Everyday Cooking | Excellent | Good |
| Value for Collectors | Good | Outstanding |
Pros & Cons Breakdown
Pros & Cons
| Brand | Pros | Cons |
|---|---|---|
| Smithey | Ultra-smooth surface; excellent heat retention; refined machining; predictable patina; reliable consistency | Heavy; slower to heat; pricier than mass options |
| Butter Pat | Feather-light for cast iron; quick heating; heritage-style casting; superb crust formation; ages beautifully | Less even heat; more demanding maintenance; higher price |
Best Use Cases for Each Brand
Use-Case Recommendation Matrix
| Cooking Scenario | Smithey | Butter Pat |
|---|---|---|
| Daily all-purpose cooking | ★★★★★ | ★★★★☆ |
| Steak searing | ★★★★★ | ★★★★☆ |
| Egg cookery | ★★★★★ | ★★★☆☆ |
| Quick weeknight meals | ★★★★☆ | ★★★★★ |
| Flipping/sauteing | ★★★☆☆ | ★★★★★ |
| Slow oven roasting | ★★★★★ | ★★★★☆ |
| Camping/outdoor | ★★★☆☆ | ★★★★☆ |
My Expert Verdict
Final Verdict Summary Table
| Category | Winner | Why |
|---|---|---|
| Smoothness & release | Smithey | Machined interior |
| Heat retention | Smithey | Denser casting |
| Fast heating | Butter Pat | Thin walls |
| Ergonomics | Butter Pat | Lightweight, nimble |
| Searing & crust | Tie | Different strengths |
| Long-term patina | Tie | Smooth vs rustic |
| Overall versatility | Smithey | Better balance of traits |
| Collector appeal | Butter Pat | Historic-style revival |
My Final Take
After months of testing, if I had to choose one for my primary kitchen rotation, I’d pick Smithey. It’s the steadier, more predictable performer—one that behaves like a refined instrument rather than an artifact. The machined interior offers the kind of nonstick behavior that makes weekday cooking less finicky.
But that doesn’t diminish Butter Pat’s charm. In fact, for anyone who loves the idea of owning a piece of cast iron that feels like a historical continuation rather than a technical reinvention, Butter Pat is unrivaled. I still reach for mine when I want quick heat or a particularly aggressive sear.
Ultimately, both brands earn their cult followings for good reason. They simply serve different cooks.
Practical Advice
How to Choose Between Smithey and Butter Pat
- Choose Smithey if you want smoothness, forgiveness, and consistency.
- Choose Butter Pat if you want agility, lightweight design, and a more historical feel.
How to Perform Your Own Heat Test at Home
- Set the pan on your stovetop at medium heat.
- Place a few pinches of flour around the surface.
- Watch where the flour browns first—that’s your hotspot map.
How to Maintain Each Type of Finish
Smithey:
- Avoid abrasive scrubbers.
- Use neutral oil for seasoning.
Butter Pat:
- Avoid sudden temperature changes.
- Season regularly early on.
- Expect a rustic patina—don’t fight it.
Best Oils for Seasoning These Surfaces
- Smithey: grapeseed, canola, or sunflower—thin oils polymerize cleanly.
- Butter Pat: flaxseed or soybean—slightly stickier oils grip the raw texture effectively.
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