Hei's Dagger (Darker than Black Cosplay)

This is a combination project I did as an example of manufacturing processes for my Mechanical Design class. It also happens to be a really cool cosplay prop.

The blade is cut in two identical halves made from 0.125" 6061-T6 aluminum plate milled on my X-Carve, polished and glued together with epoxy.

The hilt is printed in PLA and glued in place with epoxy, sealed with resin and spray-painted.

The Sheath is printed in Filaflex to give it toughness without absolute rigidity.