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After using the shape bender I used hidden geometry to work out why the end looked blunt and then added lines.

And then used Solid Inspector2 to check for errors. It actually fixed some things that were meant to repair, but not my edges which I did expect.

And then I found trying to slice through horizontally just did not work. The model is perfectly horizontal but as soon as I intersect faces it doesn’t. So lots of short pieces like for Ventress 🙂 I know that worked so this should work too 🙂

I started making fairly the overlaps to help join those pieces once printed but I’m not so I like them, so I’ll spend a little more time today on making ring supports instead.

Each hilt is more than 10 pieces. This is to better reflect the different materials (copper, silver, black) Also to allow the same print to be used as non functional and functional by having some separate blade holders able to be used simply as support, the end cap being functional with the D ring holder and screw. I kept getting errors using the bolt making plugin so I’d rather just not use that atm. It should work at a larger scale but I did find scaling could be unpredictable with curves,

These also have to be arranged in correct alignment for printing. which I will do once the connecting sections are added.

I find this quite painful and painfully slow work. A lot has had to be drawn by hand even after using tools and plugins. For example the supports I’m making can’t be just extruded as they connect into pieces on a different angle. So I have to copy from one piece and add to the first and then measure and draw to size. Luckily 5mm seems to work well so I can at least be fairly consistent with that 🙂

It’s seriously fiddly work, lots of copy paste and drawing on the inside and outside