Props The Buck stops here

[billeybob250]

Hello,

I am looking for some advice on Buck strength. I know the rule typically is "all the walls and Gyroid infill" but I'm a man who doesn't like wasting his time and is overly caseous.

Lets get to the Brass Tax, I have access to a 4ft by 8ft + commercial grade Vacuum former (but almost no one at the company knows how to use it) It does not have a PSI gage on it or an instruction manual but we know it works.

I want to make an energy sword out of transparent PETG.

I need help trying to figure out how many walls and how much infill. at 5 walls and 15% infill half of the blade will take 400g and 27 hours. so i will essentially need to quadruple that. (2 blades 2 half's each).

is this enough infill? does anyone have experience with big vacuum formers and how much pressure they exert? how strong do i go? My concern is not if i make it to strong or waist materials my concern is the buck breaking and it damage the vacuum former (they already have a damaged spot from that happening).


Theoretically if i can make this work with 1 i can make like 4+ swords in 1 sheet of film. then all i need is electronics in the hilt.

I can get pictures i can print multiple bucks i just don't want to waist the time sanding and assembling the buck for it to crack (printer time does not matter to me only man hours).

I am open to any and all advice or pointers.

Thank you.

 

[billeybob250]

Ok. so this post didnt get any traction so lets pivot the question. i will be doing something like 8 walls and 15% gyrodal infill.

But now the question is how big. The files i have are natively 1270mm(50 in) x 481mm (19in) x81.375mm (3.2 in)

There's 4.5 inches from the handle to the back of the blade and 41.2 inches from the front of the handle to the tip of the blade.

C2E2 2025 has a max length of 120-180cm depending on item type Cosplay & Prop Rules

If other people have info on other cons i would love to make sure the sword stays under most if not all con sizes.