Summary

This is an Imperial Guard baton/sword thing that I made to accompany this amazing mask http://www.thingiverse.com/thing:349643. It's slightly embellished from the actual batons in the movie, but you never get a really good look at the movie version anyway. The multiple pieces are printed out in an order that I felt was easier to print, and easier to finish.

Print Settings

Printer:

Prusa i3 XL

                                            <p class="detail-setting rafts"><strong>Rafts: </strong>                     <div><p>No</p></div></p>                                                                                <p class="detail-setting supports"><strong>Supports: </strong>                     <div><p>No</p></div></p>                                                                                <p class="detail-setting resolution"><strong>Resolution: </strong>                     <div><p>0.15</p></div></p>                                                                                <p class="detail-setting infill"><strong>Infill: </strong>                     <div><p>5%</p></div></p>                                                        <br>                        <p class="detail-setting notes"><strong>Notes: </strong>                    </p><div><p>The included .SCAD file declares a FACES variable at the top that manipulates the number of polygons used throughout.</p></div>

Post-Printing

I used a 1/2" PVC pipe (1/2" is the reported inner diameter) for the actual shaft, you can grab one at most home supply stores. A 10' section of pipe costs less than $5, so this seemed smarter than printing all of it. I cut the pipe to 1 meter, putting the total length at approximately 122cm with the top and the bottom added.

The pieces are all ordered from top to bottom in the order they fit together, top being the pointy end. I glued some of them together before fitting to the pipe, but this isn't necessary. Each part was spray painted before sliding it over the painted PVC pipe and gluing in to place with cyanoacrylate (superglue). You should deburr the insides of pieces 2-3-4 in order to avoid scraping the paint off the pipe. The rest of the pieces will cover and scratched paint.

The bottom two pieces (9 and 10) might need something in between them to make them sit flush, I used a bit of JB Weld to fill the gap.

Imperial Guard (Star Wars) Baton