So when I showed the kids thingiverse, and asked if there was anything they wanted to print, I thought my son would want a Master Sword. He’s been obsessed with Zelda for a while, and there are some cool models on there that print in a few pieces, so I figured it’d be a large, but fairly straightforward print. Instead, he asked for a Fierce Deity sword. Now there are a couple of models on thingiverse, but none of them are quite right. They either cheat by having the two blades as one piece, or the bottom didn’t look right, so we decided to just model our own in SolidWorks. This one is beyond my skill at this point, but fortunately my wife was able to put it together in an afternoon. Final model is 48" long, so obviously had to print in pieces. Some of them printed just fine:
Others not so much…:
I gave up on trying to print the middle bits vertically, and resigned myself to supports. Unfortunately, since there are almost no flat surfaces, this is how they came off the printer (some of the supports already removed in this pic):
Which meant lots of sanding and filling. Wood filler works surprisingly well here.
Finally finished the whole thing this weekend though. The mount is laser engraved on the snapmaker, and the mask is 3d printed and painted. I was going to CNC the whole thing, but the profile of the mask looks better printed and glued on: