My assignment was to make a light/lamp using only plastics and a light source (LEDs in my piece). This was my first attempt in thermaforming acrylic sheets and PVC pipe using only a heatgun. Because of size limitation of acrylic plastic material given to us (12"x24" sheets) for the project, the sword is smaller than scale as depicted in the video game. The finished dimensions is approx 24" total length x 12" at it's widest point. The smaller size however is ideal for carrying it around and for small kids to hold. It is very solid and strongly put together, but it is NOT a toy for kids or adults to swing at people, pets, or things. That could be dangerous. If I were to build another sword, Ideally I would make it from 28-32" length. The pic of me and friends holding the sword shows how bright it glows. ALL pics are not photoshopped except for the watermarks.
I made several paper mock-ups. When I was satisfied with the final paper model, I cut four identical "blades" from 1/8" acrylic plastic sheets with a bandsaw. I notched ridges on the cut pieces, to mimic the curves of the blade. The notches helped define the contour of the blade when thermaforming with the heatgun. After all four blade pieces were done, I shaped light diffusers to fit inside each blade.
For the lights, blue LEDs from amazon worked perfect. I was able to cut strips, and carefully solder wire terminals that connected to two 9v batteries and a toggle switch. The handle was made from a 1 1/4" thin PVC bathroom drainpipe, formed to shape with a heatgun. I cut an opening for the battery door, and wrapped the entire handle in a carbon fiber sticker. I made the padded soft carry case with black canvas and plush lining to protect the sword while transporting. The case has velcro closure and an adjustable 2"wide shoulder strap with a quick-release buckle.
The sword is fairly bright daytime unless you are in direct sunlight. During night or dimly lit rooms, the glow is amazing and really looks like an energy sword.
***Note on adhesives***, I used Weldon#3 to 'solvent weld' the acrylic blade halves together, but the glued edges MUST be sanded smooth and in complete contact with each other. Any gaps will result in no adhesion at those points.
Weldon#3 will NOT work for gluing the acrylic blade to the PVC handle. You either have to purchase Weldon#40, or use a universal plastic adhesive, but TEST on scrap pieces first!
I spent over 30hrs on the project because I never attempted it before. Now I can probably do it in half the time. Hope you enjoyed it.