3D Printing

What If I Don't Have A 3D Printer?

Not to worry! You can use a 3D printing service such as 3DHubs or MakeXYZ to have a local 3D printer operator 3D print and ship you parts to you. This is a great way to get your parts 3D printed by local makers. You could also try checking out your local Library or search for a Maker Space.

Edit Design

The design is modeled in Autodesk Fusion 360 and available to edit. You can adjust the pieces to print by moving or adding construction planes to cut up the parts . You can modify the sketches or adjust features in the parametric timeline.

Slice Settings

Depending on your 3D printer, you may need to adjust the slice settings. We printed all of the parts on a Ultimaker S5. These parts were sliced with Ultimaker Cura.

  • Nozzle: 0.8mm
  • Extrusion Width: 0.77mm
  • Layer Height: 0.3mm
  • Infill: 20%
  • Nozzle Temperature: 230c
  • Heated Glass Bed: 60c
  • Print Speed: 40mm/s

Blade

 

The blade is designed as a dual color print. This allows us to have built-in diffusion to minimize the amount of 3d parts required. We used Vertigo Galaxy and Blue Translucent PLA. The Vertigo Galaxy has a gold flakes that gives the sword a rustic look without the need to post process.

 

We used Blue Translucent PLA for the Blade Teeth and sword details because of its UV reactive qualities. The UV NeoPixel help to illuminate the whole Blade Saw!

Handle 

 

The handle is printed in a NinjaFlex.  It prints hollow so we can slip it over our wooden dowel to provide th.e textured design while make it comfortable to hold. 

 

Pommel

 

The Pommel is also designed as a dual color print to allows us to diffuse the eye and mouth details on the design. The coin cell breakout is mounted inside to help illuminate it!

Design Source Files

The enclosure assembly was designed in Fusion 360. This can be downloaded in different formats like STEP, SAT and more. Electronic components like the board, displays, connectors and more can be downloaded from our Fusion 360 CAD parts github repo.

Supports

 

To accommodate design details, the blade parts will require supports. We used the same Translucent material as the details for the supports with a .4mm support Z distance to make is easy to remove.

 

Support material was used for creating the recessed panels.

 

A palette knife or a Spudger can get in between the layers and Flush Diagonal Cutters break apart the supports.

Tapping Standoffs

 

A tapping tool creates threads in the built-in standoffs for fastening hardware.

 

Two halves of the blade are joined together using long machine screws.

Chain

 

The 23 blades are printed in Blue Translucent PLA and illuminated by the UV NeoPixels. The individual links of 1.75mm filament that hinge together to form the chain. 

 

This guide was first published on Sep 12, 2018. It was last updated on Sep 12, 2018. This page (3D Printing) was last updated on Aug 25, 2019.