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Let's cut the blade up! I draw some lines from above (spaced for the height of the printer bed -- 300 in this case, but sometimes I'll cut smaller pieces to avoid running a seam across a detail that would suck to sand a seam on) and then cut it up.
Time to add some internal dowel supports -- a 1" rod running in the middle, and two 1/2" ones down the sides of the blade to give it even more strength AND prevent the blade from spinning when assembling.
Now I have to cut in my handle, again with tolerances. I just draw that 0.2mm offset on the base of the handle and cut the slot out. Voila! Tolerances.
It leaves me with this (I've halved it so I can see what I'm doing) and there's a couple little weird spots -- a divot where the blade has a decorative piece, and a little notch where a tuck in the blade wings out. Neither of these can stay because then the blade can't slide out.
So I want this blade to slot out of the gold crossguard/frame. While modeling, I had cut the end of the blade down to what would fit into the slender crossguard, which made this unusual M cut -- when I've done similar swords (She-Ra's Sword of Protection) the end is straight.
I generally keep a lot of pieces separate while I model so I don't have to manually recolour all the little faces to be what colour they're supposed to be in the pretty render... so up until this point, every part that's a different colour is a different piece. Let's merge down!
I did two spears today (and a bunch of other lil things) including the Eternal Spear from Hades...
This was extremely weird to figure out but it's coming along! I now need to rig this for printing, internal support and thread holes for EL wire.
This is Malleus' staff from Twisted Wonderland. It's a Disney mobile game where Disney villains are running a magic school? Neat.
Some experiments in unusual mould making; I thought about making this piece a two-part but the seam lines seemed absolutely fucking ludicrous, so I thought... can I make it a flat-backed one-part? I added towers to the gaps/bridges so that it can rest flat.