- Personal project
- Prototyping & Experiments
- Laser cutting
I like swords. A lot. And I really, really, want a sword. A big sword. Like 5 feet long. Maybe bigger. It’s not so much an ambition as a holy crusade. But of course that comes with some challenges.
This will be an ongoing project, possibly for the rest of my life. I figured I’d start with a more anime-style sword. I’ll come back to metal swords once I’ve learned to be a blacksmith (future plans!).
One challenge with a big sword is transportation. Who knows when I might need to travel with a big sword? So I knew it had to be something I could break down into smaller pieces.
Time for some prototyping!
I’m incredibly fortunate to have access to the Brown Design Workshop. It’s a recent discovery. The workshop is huge and has a whole bunch of maker gear, from sewing to wood and metal work, to CNC and laser cutting. And it’s free to use if you sign up!
One thing I have discovered is that foam core (only $1.25 per sheet at my local Dollar Store!) and laser cutting are a fantastic combination for prototyping. I can create a 2D design, cut out the material, and test my design ideas really quickly.
The workshop has two industrial laser cutters that are perfect for cutting foam core. The maximum material size is 32″ x 24″, so that’s the biggest any single piece of my sword can be.
The initial design had three layers of foam core. I had a top and bottom layer that made the sword’s surface, and a middle layer that gave me space for a cutout and insert. The pieces just slide together. I was thinking I would use bolts to hold the pieces in place, but now I’m wondering about magnets.
The prototype worked, but there are definitely ways I can improve it. I’ll share version 2 when I have it.
