Design
From a Catalogue of European Court Swords and Hunting Swords
Background
The project was born out of a desire to make a cost-effective and historically relevant smallsword hilts that are readily available. At the time of inception, metal hilts were prohibitively expensive on long wait lists, while more affordable options meant they were made from less historically shaped components, like French epee hilts.
The design is based on the measurements of period-specific historical smallsword hilts, including the guard length and point of balance kindly provided here by the Black Boar Swordsmanship School. The goal was to provide a hilt that reflects the pommel position relative to the wrist as seen in historical examples, which is quite different to the longer French grips found on entry-level smallswords currently available.
The ambitions is to capitalise on the inherent benefits of 3D printing versus traditional fabrication, for example:
The Quillions and Knuckle Bow are formed from a single triangular profile to provide maximum strength, with the narrow edge pointing outwards in the Knuckle Bow and inwards to sit nicely next to the finger on the Quillions/Vestigial Loops.
The Ricasso curves in two directions and curved recesses provide a place to rest the thumb and forefinger.
The Shell Guard is curved as seen in more luxurious historic examples, rather than flat, which traditionally is much easier to manufacture. Being 3D printed, the guard incorporates a thickening underneath to support the Quillions and provide extra strength, while a larger washer is seated on top of the Guard so that the blade is fully supported.
Gripping The Hilt
Generally, Smallsword evolved from the Rapier with the same principal parts but reduced in size. Several different ways of holding a smallsword are described in various books but my approach and preference is similarly developed from a Rapier grip.
While the index finger goes through the finger loops and around the ricasso in a Rapier Hilt, on a Smallsword the index finger now rests along the back of what have become known as the 'vestigial finger loops', with the thumb pinching the other side of the Ricasso to give good tip control (think a conductor holding a baton). The remaining three fingers gently curl around the grip section under the Knuckle Bow.
3D-Printing
There are generally two main types of 3D printing available for home use, FDM and Resin. Resin printing generally provides better quality but is typically more brittle when using standard materials.
Files to print the hilt yourself can be found here:
Current - Version 02 - V02 3D Print Files
Old - Version 01 - V01 3D Print Files
Resin - Anti-Impact ABS-Like - Current method
The goal is to replicate the FDM properties with sufficient strength and a little flexibility and a good elongation at break point. We are currently using: 70% Siraya Tech Blu Resin Black Nylon and 30% Siraya Tech Tenacious Resin Obsidian Black
https://siraya.tech/products/blu-tough-resin-by-siraya?variant=40164575215725
https://siraya.tech/products/tenacious-resin-flexible-resin
FDM - Carbon Fibre Reinforced Nylon (PA6-CF) - Previous method
Carbon fibre-reinforced nylon has superior impact and tensile strength compared to other FDM materials but is more challenging to use successfully. It requires specialist equipment and more post-processing. The CF hilts were hand sanded, annealed (baked) at 100 degrees centigrade for two hours then soaked in mineral oil. It allows much thinner parts but with an increased water absorbance rate. This has also been printed in Tough PLA and a few other materials, which works but you just need a few spares for breakages!
Non 3D-Printed Components
For anyone wishing to print a hilt themselves, these are the metal parts required:
BLADE
Non- electric triangular epee blade
Size: #2 with a French M6 tang (no cant and cut down to 138-145mm)
*The hilt should work with other epee blades with a long French M6 tang that will need to be cut down to size.
**Sometimes re-threading is required.
*** Successfully tested with Leon Paul blades.
GUARD WASHER
M8 square hole washer DIN 440
(M6 washers fit most blades but some have a slightly wider tang at the top requiring M8)
Supplier: Accu
POMMEL WASHER
M6 solid countersunk NFE27-619
Supplier: Accu
POMMEL
25-30mm steel ball knob with an M6 thread
Size depends on the weight of the specific blade and preference for the Point of Ballance
Supplier: ebay
Comparison with Historical Measurements
Weight 270g
Overall length 970mm
Grip length 85mm
Blade length 820mm (Allstar #2 triangular)
Point of Ballance in front of the hilt 60-80mm
Shell guard 80mm x 70mm
Measurements below are available at
