Laser Cut MDF Cosplay Pistols




About: Hobbyist prop maker churning out geeky stuff for myself and others!
Several years ago, I was commissioned by a cosplayer to build replicas of Dante's twin pistols, Ebony and Ivory, from the Devil May Cry video game series. I was still new to prop-building so I cut the body of each gun out of 3/4" MDF and glued on bits of plastic to make them look like their game counterparts.

They turned out pretty good and the client was happy, but they were never perfect enough for my tastes. It's difficult to get the machined look with hand tools and almost impossible to engrave graphics which is a distinctive feature of these guns.

Step 1: Laser Cutting

For the new version, I refined the detail in Adobe Illustrator and planned out the parts so they could be built using layers of laser-cut MDF. This would allow for maximum accuracy as well as the engraving on the barrels.

The body of each gun was cut from 3 pieces of 1/4" MDF, with a gap in the middle section for a trigger and hammer, which were also cut from 1/4" MDF. I also left a gap in the middle section for a faux barrel. Raised areas like the side of the slides were cut from 1/8" MDF.

Step 2: Modification

Since the laser only cuts perpendicularly to the wood, I had to bevel and round certain bits with sandpaper, files and the Dremel. Other pieces, like sights and slide locks, had to be built by layering the MDF and adding detail.

Step 3: Scratch Building

Other parts were just easier to cobble together from scratch with available materials.

Step 4: Assembly

Now that you have everything built, you can start to assemble the guns. I needed multiple copies, so I made silicone molds of all the parts to make plastic resin pieces. Paint all the parts before assembly. Use 2-part epoxy to glue the gun halves together and attach all the little parts.

Step 5: Finished

Laser cutting not only saves a ton of time cutting out parts but its precision also lends itself to making replica guns. To replicate the look of machined parts by hand takes time, effort, and skill. Laser cutting, like any tool, makes it easier and faster to get cleaner results.

If I was fortunate to win the Epilog Zing 16 laser, it would be a major time saver. With the type of custom fabrication I do, a large part of my day is cutting and cleaning up parts. What might take me an hour could be cut by laser in minutes! Time is the only resource you can't get more of!

If you'd like to build your own Devil May Cry pistols, you can download my plans and laser files HERE.
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    11 Discussions


    Question 1 year ago on Introduction

    Hello, do you still have the files to make this?


    3 years ago

    link dont worj!!!!!


    4 years ago

    can u send me the files ? please


    4 years ago on Step 5

    hi man... i would love to build these (or alt least try)... your dropbox link to the laser files doesn't seem to work :( could i possibly get that file from you?? many thanks :)


    5 years ago

    I really want to buy a pair... Only because I can't get my hands on a laser cutter :(


    5 years ago on Introduction

    Excellent build!

    One tip, though: to get a cleaner painted look for the slides, cut them in one pass, paint them, then run them through the laser again with a mask to etch them. Then, paint fill the etched part, and remove the mask. Make sure your paint is dry before the etching pass, and that your mask won't pull off the paint. Then just touch up the edges if you need to to make them blend better with the rest of the slide. This will allow you to paint with the precision of the laser cutter.

    It adds a couple steps, but I think it'll pay off in precision!


    6 years ago

    Where can I buy your pistols , but normal pistols not DMC ones


    6 years ago

    Wow, very beautiful