A couple moths ago, my company acquired an old mold printer. They tasked me with setting it up and testing it. I always wanted a batarang, so I took this opportunity to make myself one.

Step 1: Tools and Equipment

The items used to make my batarang are listen below.

Z-Printer 310 Plus (prints sand molds to pour in)
Some molten aluminum
Grinding and cleaning tools
SolidWorks or equivalent modeling software

You can also just 3d print the batarang, I attached the solid model if youd like. Scale as appropriate.

Step 2: 3D Printing and Pouring

Make any changes to the model that you'd like, its a typical design I claim no credit for. For the printer I was using, it required me to model the actual shape of the mold. After doing so, I imported it to the printer as an STL file.

After two hours, the mold was done being printed. Using an air compressor, clean the molds with a light air blow. After it is clean, stick it in an oven at 200 degrees F for half an hour to cure. Assemble the mold and put some weight on it. The weight is so the metal doesn't lift the mold apart and spill out.

Once ready bring the metal temp up to 1350, the part is thinner so you want to pour it at a nice hot temp. Pour it and let it cool for an hour.

Step 3: Finished Batarang

Clean the batarang using available tools. I used a band saw and grinding belt and scotchbright. For those that can't pour metal, you can use the attached file to 3d print one out . Justice calls....