This is a combination project I did as an example of manufacturing processes for my Mechanical Design class. It also happens to be a really cool cosplay
...Plus prop.
The blade is cut in two identical halves made from 0.125" 6061-T6 aluminum plate milled on my X-Carve, polished and glued together with epoxy.
The hilt is printed in PLA and glued in place with epoxy, sealed with resin and spray-painted.
The Sheath is printed in Filaflex to give it toughness without absolute rigidity.
