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Made by kbhuwalk · UNLISTED (SHOWN IN POOLS)

Exploring the use of clay as a modeling medium to design a sword handle

Created: March 18th, 2019


 For this project, I wanted to build a sword handle with an artistic pommel. Initially, I wanted to build a replica of Orcrist (an elven sword from The Hobbit trilogy). However, the handle had three separate pieces. I was advised to build something that was a single piece for the next project. The next sword handle I wanted to replicate was Master Sword from Legend of Zelda. However, the model was extremely detailed and I knew that it would be very difficult to complete it in time and maintain a good fidelity. Finally, I took a hybrid approach to build my own model with the help of the framework of Master Sword.


The internal structure for the handle was made out of laser-cut plywood stacked on top of each other (used Slicer to slice them properly). There was a total of 44 individual pieces that needed to be put together. Since many of the dowel holes didn't align properly, I used solder wire instead along with wood glue to join the separate pieces together.

However, wood was not my first choice of material. I had initially thought of using cardboard for the internal frame. After setting the cardboard on fire a few times, I decided it would actually be quicker just to use plywood.

All the individual pieces that made up the internal frame
Img 1159.thumb

After creating the internal frame, I started applying a layer of clay on top. At this point, I had a vague idea of how the pommel would look like. I just didn't know how to build the flame-like 3d structure I wanted.


I also laser cut a couple of custom arc to help me get a smoother finish and relatively accurate diameter for the different sections of the handle.


The final step was to use a damp sponge to give it a finish and add some additional detailing.

Process Mood Board
My post.thumb
Sword concepts for inspiration
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24-672 Special Topics in DIY Design and Fabrication

· 22 members

Offers students hands-on experience in DIY product design and fabrication processes. Students work individually or in small groups to design customized and personalized products of their own and bu...more


Exploring the use of clay as a modeling medium to design a sword handle