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Small and compact project covering wide area of many technical skills. Project covered skills such as prototyping (using fusion 360), 3D printing, mould making and casting both resin and metal. This is a continuation of my sword making project which included developing abilities in operating plasma cutters, grinding machines etc. Developing skills in digital design allowed me to approach this project in new and more advanced way which ensured success of the process.

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Grinding and cleaning the blade

Finished result

A year later I decided to revisit this project. Armed with completly new set of skills I decided to tackle this project again (3D printing project was run remotley during the national lockdown)

Sword hilt and part of the mould insert designed in Fusion 360

Printing the hilt

Ready for asembly

3 part 3D print will be used to create 4 part heat resistant sillicone rubber mould

Figuring out where to insert sprues (when casting material enters the mould we must ensure that the air trapped inside the mould have some escape routs)

4 part mould ready

Testing the mould with resin cast

Resin cast came out prefect. No major air bubbles indicate that there is no need for additional sprues

heating up the pewter

First cast looking good

Pewter cast ready for polishing and buffing

3d print vs. resin cast vs. pewter cast

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