Ergonomic weapon handle (LARP/Combat Sport sword/dagger)

Intended for use with lightweight “LARP" weapons, aka “boffers”, constructed using a solid, cylindrical core such as extruded carbon fiber rods.  

Print using PETG, ABS, nylon, or other durable material, and use at least 4 perimeters on a 0.4mm nozzle.  DO NOT use PLA or other brittle material unless intended as a prop or for use in “light touch” LARP play.  

OpenSCAD model source is included so it can be adapted to a specific core, hand size, or overall length/size as desired.  I have included some defaults but this model is intended to be adapted as needed.  

“test cylinder” is for testing the fit of a specific core.  Even without using glue, the core should fit into the handle snugly and require a significant force to insert and remove.  When gluing, use glue that is appropriate for the application, such as a cyanoacrylate glue or an epoxy that is compatible with carbon fiber.  Will likely require some fine-tuning to a specific printer, filament, nozzle, and extrusion ratio.  

Important note for printing:  If it's going to be used for anything other than “lightest touch”, and you aren't using solid (100%) infill, I highly recommend setting Infill→Advanced→Solid infill every … to 15 or less (for a 0.25mm layer height).  Otherwise the core will only be supported by infill throughout most of the handle, and held in place only by the solid infill at the very front of the handle.  If used like this, it creates a massive “stress point” which could break the handle or core at this point.. not a good thing!

Amazon links:

Carbon fiber Core best for short weapons, 3 feet or less (used for the included .scad files): https://www.amazon.com/dp/B09QLG8FNN?psc=1

Wider Carbon fiber core best used for short to medium size weapons, 4 feet or less: https://www.amazon.com/dp/B09Q8JV1W8?psc=1

“fencing grip 4" is a low profile handle designed for use with gloves.  It is a good starting point for any parameter adaptation.  “fencing grip 2” is an older handle that was designed for use without gloves, or for people with large hands. 

Important note: “fencing grip 2” may require more extensive padding around the pommel area in order to be safe if used in a high-impact combat sport.  “fencing grip 4” has been designed so it only requires a single cylinder of padding on the end of the pommel.  “fencing grip 4” and “fencing grip 2” are intended for use with 10mm cores.  “fencing grip 5” is similar to “fencing grip 4” only slightly larger and intended for use with 14mm cores.  “fencing grip 6” is similar to “fencing grip 5” only slightly less curved and with the rod protruding slightly farther through the handle.