We've used craft sticks in our previous Gun Blade project as internal supports. This is an easy way to join parts together.
These sticks are inserted into the slots and marked for measurement - these need to be cut down so everything fits and looks flush.
The tolerances for the slots are going to vary depending on your printer, but you can trim off the sticks corners to fit them into place - just try not to break them by jamming them in, because that could be bad!
The cross guard has two slots that go near the bottom of the blade. These sticks help to align the blade while keeping them from rotating.
You don't have to glue the sword if you plan to travel with it. Just make sure the tolerences are tight enough so the blades don't fall apart while in battle.
To make the hilt of the sword, we’re using a 7/8th wooden dowel - those are just the right diameter for a grip, so we can use real wood with our 3D printed wood…which is like, meta.
The pommel has an opening in the bottom and fits into the dowel. You’ll need to cut the hilt down to size to fit your hands - we measured ours so that it can fit two hands.
You can insert the dowel into the printed parts and mark them to get the measurement of the hilt.
So there you have it, extruding wooden filament to make wooden cosplay props. Again, this is BambooFill - Bamboo PLA filament from the guys at Colorfab.