3D Printing

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3D Printed Pieces

The Energy Sword is split into twenty main pieces. The top and bottom end of the handle parts, the front and back of the main handle and the eight pieces of the blades. 

The blades are split into four main pieces for the front and back. Each side of the blades are different and snap fit together. The parts will need to be glued together using adhesives.

The top and bottom handle pieces feature pockets that allow wooden craft sticks to be inserted into them - This aligns the parts together and holds them in place while the glue sets.

Gluing blade parts

The blade pieces are glued together with super glue and then reinforced with E6000.

Start by sanding the edges of the blades to ensure they line up flat together. Apply super glue to the one of the edges and then hold both pieces until they hold together. After both side are dry, glue the next part of the blade together until all of the pieces are attached. 

Once all of the blades are held together with super glue, apply a generously amount of the E6000 to the inside of blade, were each blade piece meets. 

Don't apply E6000 to the walls of the blades, this could prevent the two sides of the blades from snap fitting together.

Allow the E6000 to dry before proceeding.

Filament Materials

We recommend using PLA material to reduce wraping while 3D printing. The parts can be printed in different types of filament, such as ABS, PET or Nylon.

Slicer Settings

To slice the parts, we used Simplify3D. We recommend using the settings below or use them as reference. We 3D printed these parts on a Type A Machines Series 1 3D printer. If you have Simplify3D, you can download our profiles below.

handle-top.stl

handle-btm.stl

blade0.stl

blade1.stl

blade2.stl

blade-tip.stl

 

blade0in.stl

blade1in.stl

blade2in.stl

blade-tip-in.stl

 

230c extruder
50mm/s print speed
120mm/s travel speed

front and back handles require supports for the standoffs


print the handles at a higher resolution for smoother parts (.15 layer height)


No supports for the blades

handle ends take about an hour to print

front and back handle take about 4 hours to print


blades take an hour to print using a .8mm nozzle

 

Tolerances

The pocket areas of the parts may have tight tolerances. Test the tolerances by inserting a wood craft stick into each pocket. If sticks will not fit into the pockets, you may need to use a craft knife or filing tool to open up the area.

Customize The Design

The parts where designed in Autodesk Fusion 360. The design has been made public, and available to download in different formats. If you'd like to use a different CAD software package, you are free to import the files and remix them.

This guide was first published on Jan 27, 2016. It was last updated on Jan 27, 2016. This page (3D Printing) was last updated on Jul 19, 2019.