3D Cosplay Prop Kit

This easy-to-build kit features parts with screw-threaded ends. It's also easy to take apart and break down, making it great for transport. Each part is printed in a specific color. Parts are designed to 3D print without any support material. Best suited for large printers with minimum build volume of 250mm x 210mm x 210mm. Download the files and 3D print your own keyblade!

3D Printed Parts

These parts were 3D printed using a special blend of PLA filament. The PLA Extrafill from Fillamentum appear to be infused with glitter giving parts a semi-glossy surface finish. These wasn't any post-processing done – These parts are straight off the printer. These filaments give parts a texture makes layer lines appear less visible at a distance.

This prop is separated into parts that are designed to be modular. The assembly is easy to build and the parts snap fit together. The build uses hardware fasteners for a ridge frame that is sturdy and durable.

The design source files are open source and available for remixing. This guide will provide a parts list, slice settings and assembly instructions.

3D Printed Parts

The parts in this kit are designed to be 3D printed with FDM based machines. STL files are oriented to print "as is". Parts require tight tolerances that might need adjustment of slice settings. Reference the suggested settings below.

Wall Line Width

The blade is comprised of hollow tubing that prints with minimal infill. The pipe is made from four pieces that feature screw-threaded ends. With a shell thickness of 1.5mm, the walls of the cylinder is made from just the inner and outer perimeters. Adjust the "wall line width" to generated a similar tool path in your slicing software.

Tolerance Testing

An extra part is included with the kit, tube-tester.stl – This part is meant to test your printers slice settings. Print two and see how well they screw together. The outer pattern should line up properly. These parts  use the same tolerances in the screw-threaded ends. There's a small gap between the mating threads to accommodate for expansion during the printing process. This also gives the surfaces some room so that the parts don’t grind together when twisting them.

Filament Colors

List of filament colors used in this project. PLA is by Fillamentum.com these are from their premium filament line of material.

• Vertigo Galaxy PLA
• Vertigo Gray PLA
• Vertigo Starlight PLA
• Gold Happens
• Rapunzel Silver

Parametric Customization

Need to change the diameter of the screw? How about using different heat set inserts? The parts are setup with user parameters, so it's easy to change a value and automatically update the features in CAD. Tolerances use a "gap" to give clearance between mating surfaces – slight adjustments make big differences.

Screw-Threaded Parts

Most of the tubing pieces feature screw-threaded ends allowing the parts to simply screw together. This uses the coil feature from Fusion 360 to create threads with custom size, pitch and height. Watch my Layer by Layer tutorial below for a deep dive on how to design parts with these features.

Knurling Textures

The grip in the handle features knurling texture that wraps around the cylinder. This design technique is achieved using the coil and circular pattern features in Fusion 360. Watch my Layer by Layer tutorial below for a deep dive on how to apply knurling to your parts.

Handle Assembly

The handle is comprised of six individual pieces. The cross guard requires M3 screws and heat set inserts. The end cap and connector parts are keyed and snap fit into registrations in the cross guard.

Required Hardware

• 8x M3 button head machine screws
• 8x M3 heat set inserts

Blade Assembly

The blade is comprised of seven parts. The collar joins the tubing to the handle. The pipe extension is printed twice to lengthen the tubing. The key wards slide into the v-slot on the pipe-key.stl part. The pipe-top-cap.stl part is designed to snap fit and locks on top.

Installing Heat Set Inserts

The handle requires threaded inserts for joining the halves together with screws. The term "heat set" is named after the installation process. Place an insert on top of the mounting hole. Use the tip of a soldering iron to heat up the insert and slowly press down to install. I  suggest using a vise to help keep parts in place. I used a long screw to test the straightness so you can go back and reheat if you need to.

• Heat-Set Solder Iron Tip

Install Grip

The grip features registration keys on both ends. The cylinder is symmetrical so it can fit either orientation. Line up the notches on the handle halves and press to snap fit into place. 

Install End Cap

The pommel, or "bow" of the keyblade is made from two pieces that are glued together – handle-ring.stl and handle-endcap.stl. The endcap part features registration keys that slot into the bottom of the cross guard halves.

Install Collar Connector

The handle-connector.stl part is fitted on the opposite end of the cross guard. It also features registration keys that slot and snap fit onto the cross guard halves.

Clamp & Secure

Place the other half of the cross guard and clamp it onto the assembly. Hold the parts together while installing machine screws. Insert and fasten 8x M3 x 6mm long machine screws until fully tightened.

Install Key Wards

The key wards feature an edge that slides into the v-slot on the pipe-key.stl part. Install the key ward with the drafted angle going in first – Reference photo for correct placement. If tolerances are too slight to fully slide in, use a mini rubber mallet to hammer it in. Place the pipe-top-cap.stl part over the tubing with the notches lined up. Use the edge of the table to apply firm pressure to snap fit and lock it in place.

Install Pipes

Connect the two pipe-extension.stl parts together. Then, install the pipe-base.stl part onto the bottom of the pipe extension. Proceed to install the pipe-key.stl part onto the top of the pipe extension.

Install Collar

Screw the handle-collar.stl part onto connector on the handle assembly. This piece joints the handle assembly to the blade assembly.

Install Handle to Blade

Twist the collar onto the tubing of the blade assembly. Firmly twist to tighten until the cross guard and key wards line up properly. Take a moment to disassemble a few times to get the threads to smoothly screw together. The blade and handle can be removed for storage or putting in a bag for traveling to an event.