3D CAD Sword “Flugel”

I’m fascinated by weapon designs in video games, anime, and manga: the bigger they are, the easier they are to use. I decided to design a sword that is as big as possible while still being feasible to make and use. This became my primary requirement.

After one of my co-ops, my supervisor offered to prototype aluminum sheet metal and simple CNC machined parts if I ever needed. These manufacturing methods became my primary constraints.

Flugel (German for “wing”) is the second of two designs that I made in SolidWorks. The sword measures about 3′ end-to-end and is 5.5″ wide.

Currently making adjustments to the handle pieces to allow for easy assembly and manufacture.


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