This is an evolution of my original Collapsible Katana design with a some improvements:
- The kissaki is now included as part of the innermost sword section, which means no assembly is required to print it. This results in a much cleaner finish on the tip of the sword.
- The five blade parts are all printable using Vase mode, which will make them smoother yet and will probably print faster.
- Handle, guard, guide, and pommel can be printed without supports, choose orientation to minimize overhangs and you'll be good.
- The blade now has a habaki (guide) at the base of the blade where it enters the Tsuba. This makes the sword look more correct when extended, but does stick out more when it's retracted. On the whole I think it's worth the addition.
- Reduced the curvature of the blade slightly as the first one felt too curved to me. This feels better, but I could probably lower the curvature even a little more.
Assembly:
- Slide the blade sections together in order.
- Slide the blade section group into the handle and test to make sure everything slides nicely.
- Glue the guide (habaki), handle (tsuka), and guard (tsuba) together with a small quantity of cyanoacrylate glue. I used Loc-Tite instant-bond.
- Glue the pommel onto the end of the handle.
