If your sword fights keep ending in a draw but you’d like to do them in style, there’s no better way than dressing up as the Black Knight from Monty Python and the Holy Grail.
Maker Christopher Adam (who goes by @SuperCoolRobots online) has 3D printed the Black Knight’s belt buckle, helmet and sword, with the latter two being the topic of discussion today.
Adam tells us that both parts were modelled in Fusion 360 using unexpected reference material. Images from the movie proved too dark and grainy to get precise detailing, so a collectable figure of the character was used for this purpose instead.
The helmet took about a full day to complete with the sword eating up more time at a day and a half. Much of this time was spent scaling and getting the dimensions perfect to fit Adam while still being accurate to the movie.
Printing the helmet took a whopping 62 hours after it was split into seven sections to fit its printer.
Once finished these pieces were joined together with UniBond epoxy and held together with tape while it dried. Once assembled the helmet measures in at 25.2 X 41.2 X 27.3 centimetres, but those looking to print their own should scale it to fit their head.
After sanding over the joints, Hycote filler primer was applied followed by another round of sanding and finally the Rust-Oleum black metallic paint.
While the colour of your filament usually doesn’t matter for parts that are going to be painted, the black PLA used here means that the inside of the helmet didn’t need to be finished as it was already the correct colour.
The sword went through much of the same process as the helmet, with a few key differences.
It took less time to model, for one, at about half a day’s worth of work.
From there it was split into nine parts which together took 38 hours to print. Aside from the plastic there’s a carbon fibre rod that’s a metre long hidden inside of the blade. A 4.2mm diameter hole was added to the interior of the blade during modelling, and the rod was glued into place to give the sword rigidity.
The rest of the pieces were also joined with UniBond epoxy (around five tubes of the stuff was used between these two pieces) resulting in a pieces that’s 125.8 centimetres long and 33.7 centimetres wide at the crossguard.
Grey PLA is used here in place of black, but received the same sanding and filler combo as the helmet before being finished in two different colours of Rust-Oleum paint – matte black for the hilt and gun metal metallic for the blade.
Adam ends by telling us that he considered weathering the two pieces but decided against it. The paint used on the helmet does leave it with a “hammered” metal look, so consider that for your version.
You can see the sword below as well as the finished costume as worn at London’s October Comic Con. We’re not sure about this Monty Python / Game of Thrones crossover, but we’ll give it a chance.