Tough sword - collapsible or pool noodle options!

Why I designed this:

My 5 year old loves this kind of stuff. Most of the swords I've found for printing wouldn't hold up to his abuses. It was also a fun experiment, since I've never done one of these before.

Printing notes:

Layer height: .15 or finer is ideal to prevent binding when extended aggressively.

Recommended Material: PLA works, but ASA or ABS would be better for strength.

Supports: None

Infill: 15% Gyroid or triangle

Walls: 3+

Other Modifiers: Print as oriented

Material Quantity: ≈180grams

For multi-color, the blade can be printed separately from a different material.

I printed from PLA on Centauri Carbon at .15 layer height with 15% triangle infill in 5h45m.

Cautions, notes, and updates:

Don't put your eye out.. or your brother's.

The outer shell of the blade slides into the groove in the handle. It fits nicely without glue, but if you're going to get aggressive, a bit of adhesive along the blade or handle groove is recommended. 
 

7/24/25 I’ve added a foam pool noodle adapter for safer sparring matches!

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Thanks, and Happy Printing!

Also check out:

https://fabtechmfg.square.site/