Excalibur (Fate/Stay Night)
Introduction: Excalibur (Fate/Stay Night)
For my SIDE Project in Ms. <PERSON>'s Principles of Engineering Class, I made a life-sized replica of Fate/Stay Night's Excalibur, a two-handed sword utilized by the one of the protagonists, <PERSON>. More projects can be found on her website.
I was primarily inspired to replicate Excalibur from a YouTube video where the craftsman made a life-sized replica of the sword using cardboard. Throughout my process of creating various parts of the sword, I occasionally used his measurements (primarily for the blade's decoration and engraving). While I primarily used my own replica of the sword (though a much smaller sword meant for a figurine of <PERSON>), you can use his measurements if you do not have any measurements or small replicas of the sword. Have fun!
Throughout the process of creating the sword, I familiarized myself with the CAD program Fusion360, as well as the PrusaMini and the Original Prusa i3 MK3S.
Supplies
For this project, I used:
PLA Filament (filament can differ depending on your preference of color/material, but I used)
* Prusament PETG Ultramarine Blue
* Prusament PLA Galaxy Silver
* PLA Silk Gold from Hatchbox
Assembly and Final Touches:
* 1/2" Diameter Wooden Dowel (98cm long)
* Paint: Acrylic Paint and Acrylic Brushes (color/material can differ depending on your preference)
* Loctite Super Glue (Brand does not matter)
* Sandpaper
3D Printing:
* Original Prusa Mini
* Original Prusa i3 MK3S
Software:
* Adobe Illustrator
* Fusion360
* Prusa Slicer
Measurements:
* Dial Caliper (optional, only if measuring via figurine replica)
* Ruler
* Pencils and Paper, Scissors
* Measurements for the Replica
+ Cardboard Youtuber
+ Someone's measurements of their official Excalibur Replica
* Small Replica of Excalibur from Figurine (optional, not needed)
Step 1: Planning
Using the measurements from the Cardboard Excalibur Youtuber and/or the Redditor, you can CAD the parts on Fusion 360. However, if you wish to use your own measurements like I did (optional), take an optional step to measure your miniature replica!
I split the sword into four parts and connected them internally with a wooden dowel (shown above for easier visual understanding):
* Blade
* Hilt
* Guard
* Blade Decoration
The dowel is 1/2in in diameter and I cut mine to 98cm (I purposely made mine slightly shorter than the maximum length of it in case of any complications when assembling, there is slight wiggle room inside the hilt but it is not visible and does not cause any problems).
Step 2: CAD Hilt
The hilt is the easiest of the four parts to CAD first.
The first image is how the hilt is supposed to look like, while the second image is a side view.
To make the hilt, I first made a 25cm line (this is the length of the hilt), then divided it depending on my measurements (I had to estimate where most of these divisions are. Divide the measurements according to where you measured had the biggest change in diameter size throughout the hilt. The third photo are my estimated increments.
Then with each increment (you should have 6 breakpoints= 8 different radii because the top and bottom part of the hilt). For each breakpoint, the order should go:
1. 3.8cm (The bottom of the hilt)
2. 4.4cm
3. 737
3.8cm
4. 3cm
5. 2.5cm
6. 3.5cm
7. 6cm
8. 4cm (The top of the hilt, connects to the guard)
After, loft every part of the hilt from 3-8 (exclude 1-2! Loft them separately and do two: one for 1-2 (bottom cap)). Your hilt should look the exact same of similar to Photo1.
Next, split your hilt. (There are two different colors for the hilt. While the hilt is mostly blue, there is a top and bottom part of gold. Also, the PrusaMini is too small to accommodate the entire length of the blue part of the hilt). I split mine at #7's plane (top gold cap) and #5's plane (middle of the hilt). Your hilt should be split like Photo2.
After, extrude a 1. 276