Development
This project began with extensive research and design planning to ensure the Finn Sword replica would be as accurate as possible. Multiple screenshots and artwork from the Adventure Time series were collected to replicate the scale and shape of the sword accurately. Using Blender, I created a precise 3D model of the Finn Sword, capturing every curve of the leaf-shaped blade and the distinctive hilt with its embedded gem.
Initial prototypes were printed using standard PLA material to test the fit and accuracy of the design. These iterations helped refine the model through several versions until we achieved the final product shown here.
Final Production
To ensure the sword was both durable and visually appealing, a blend of PLA+ and PETG materials was selected. These materials provided the necessary strength and a smooth finish, ideal for a high-quality prop. Once printed, the components were carefully assembled.
The electronic components were fixed into place inside the hilt and handle sections, hidden away behind the translucent gem embedded into the hilt. Any seams were smoothed out to ensure a seamless appearance. The LED light-up feature was a critical aspect of the project. High-quality 5050 chip LEDs were installed behind the gem, with the wiring neatly routed through the hilt.
To ensure convenience and longevity, a rechargeable lithium-ion battery was integrated into the grip. The battery setup included a USB-C charging port, discreetly hidden in the pommel, providing an unobtrusive and practical solution for recharging.
