3D Printed Sword

I worked up this project so that my princesses could also slay dragons, it works just as well for Knights, Princes, and Spartan Warriors.

The Sword is a simple design that uses a Home Depot Yard stick as the core.

The blade of the sword is made from a home depot yard stick (paint department $.98), I added a layer of chrome paint for flourish. The handle is wrapped with hockey tape for a better grip and look. The Cross-guard and Pommel were 3D printed using PLA.

Begin by printing the Cross-guard and Pommel. I used a low resolution setting with 3 shells and 20% infill, this gave me a solid part that can take some abuse from the kids (me). The parts I designed are specific to the yard stick that I purchased, you may need to scale the parts a bit to get a nice fit.

I designed the parts for a tight press fit, this way the handle stays together without adhesive.

The blade must be forged in the white hot volcanic fires of HooMeeDe-pot by the dwarves of Krylon...

All kidding aside, The yardstick was sliced in half using a chop saw, i cut the blades to 18" this seems to be right for smaller children. Also the shorter length slows the tip speed (hurts less). I then shaped the tips into a more blade like design and blunted the tips for safety.

A quick coat of silver paint finished the blade off. You could also use bronze or copper paint for your spartan warriors.

The plastic printed parts are designed to be pressed into place, using an exacto knife I beveled the back edges of the blade slightly to help them start into the Cross-guard and Pommel. Be careful using the razor blade my efforts earned me two stitches, and mild disapproval from my wife.

If the blade seems loose, a bit of two part epoxy would be a fine addition.

The handle was wrapped using hockey tape.

• Start by attaching the tape to one end of the handle and unrolling it 12-18".
• Hold the sword in the air with the tape roll hanging below, spin the roll until the tape twists into a thick string.
• Then wrap the twisted part of the tape around the handle with 1/4"spaces in between.
• When you reach the other end of the handle you should run out of twisted tape.
• Cover the twists with a single layer of tape to finish the look.

Arm your favorite Knights or Maidens and send them into battle. And remind them not to actually slay the dragon (dog)