3D Modeling

The Aquila Favonia was modeled in Autodesk Fusion 360. The model includes all hardware, rigging, and electronics. Nearly all the components were sculpted with T-splines in the form workspace.

There are three major sections - the blade, the guard, and the handle. When finished, the sword is designed to separate into these three sections for easier transportation.

The major sections further subdivide along color lines wherever possible to minimize masking when painting. These subdivisions will be glued together.

Casted Parts and Mold Boxes

The blade edge and small gem (blue parts above) were to be cast in a transparent blue resin that will allow light to shine through. Pour spouts and vents were added to the blade model.

Additionally, the mold box for the blade was also modeled in order to do a matrix mold - this saves both time and money when doing a large and oddly shaped part like this. The mold box will be 3D printed and assembled around the finished and polished blade part. Silicone will then be poured into the spout as show, sealing the vents as the level rises. After the silicone cures, the mold will be flipped over and cut along the top side where the pour spout and vent holes are. The master will be removed from this cut which will leave a cavity to pour resin for the final part.