Trollhunters Sword of Daylight

myminifactory

My daughter had her heart set on the Sword of Daylight from Trollhunters, and as a newcomer to 3D printing, I decided to take it on as a learning project. Using Fusion 360, I carefully modeled each piece to fit snugly onto a 5/8 inch wood dowel that's precisely 25.6 inches long. To add extra strength to the seams, I designed small connectors that would help hold everything together. However, when I assembled my sword, not all of the connectors fit perfectly - I suspect it was due to a slight distortion in the base of each print. The seam where both connecting sides were printed on top fit seamlessly, but if I did this again, I'd definitely print the blade pieces on a raft to minimize that issue. I ended up printing six connectors, but only four were needed, and 15% infill proved sufficient for added strength. If I were to reprint this sword, I'd likely opt for a higher infill on the tip piece and the handle. The hilt was the only part that required supports, so I designed the inner holes with 45-degree angles to ensure smooth printing. After gluing all the pieces together, I blended the seams using Bondo and sanded them down to create a seamless finish - though I didn't have time to perfect it as much as I would've liked. This project was a massive undertaking, taking approximately 45 hours to complete on my CR-10 printer. The photo shows how I oriented each print for optimal results.