Design

Background

The project was born out of a desire to make a cost-effective hilts that can be combined with standard blades to that they are readily available to people who want to try HEMA without the large buy-in.

At the time of inception, metal hilts were prohibitively expensive and on long wait lists, while more affordable options were very hard to find and made from more modern components.

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 ambition is to capitalise on the inherent benefits of 3D printing versus traditional fabrication, for example:

The Quillions 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 Vestigial Loops.
The Ricasso curves in two directions with a further curved recesses to rest the thumb and forefinger on which was developed across 20 different versions!
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.

From a Catalogue of European Court Swords and Hunting Swords

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.

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)

Supplier: Allstar or PBT UK

*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

Smallsword Measurements by Black Boar Swordsmanship School

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