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.

 

[N8TEBB]

oop didn't know c2 had a max prop size. I've carried my massive gravity hammer around for the last two years without a word, it's just barely over 180cm

Brother Drim weren't you looking for someone with a vacuum former this large??

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).

I think your idea of 8 walls is sufficient. It may be overkill, but why try and find out? If you overbuild it you'll know for sure that it won't lose its shape. 15% infill is good I think.

But now the question is how big.

This energy sword is 85cm (33.5"). I'm 6'3" in armour for reference. The sword is a very useable size and feels good to hold on to. I wouldn't want to go much bigger than this.

 

[Brother Drim]

oop didn't know c2 had a max prop size. I've carried my massive gravity hammer around for the last two years without a word, it's just barely over 180cm

Brother Drim weren't you looking for someone with a vacuum former this large??


I think your idea of 8 walls is sufficient. It may be overkill, but why try and find out? If you overbuild it you'll know for sure that it won't lose its shape. 15% infill is good I think.


This energy sword is 85cm (33.5"). I'm 6'3" in armour for reference. The sword is a very useable size and feels good to hold on to. I wouldn't want to go much bigger than this.
View attachment 370107

I was in fact looking for a large vacuum former and Billy and I have chatted a little about it already!

Thanks for looking out though