This is a toy version of the Ninjago Sword of Fire. I actually cut this out on a Shapeoko 3 CNC machine in hard maple. If anyone wants to try 3d printing, I recommend doing it in two halves and then gluing together with some super glue. Post a pic of the print make if you do print it, would love to see how it turned out.
I did not recreate the cartoon model exactly because I wanted to CNC this and make it a sturdy kids toy. For this reason I squished the length down so it would fit in my Shapeoko and I did not make the bevel go to a sharp point because it would be dangerous and also not last very long.
The original sword can be seen here:
http://ninjago.wikia.com/wiki/Sword_of_Fire
How did I cut it out? Well I used a method called window machining. Basically you cut one side, then flip the wood and cut the other side. When you cut the final outline of the part you leave small tabs on the perimeter so the part doesn't go flying, then cut the tabs at the end with a sharp knife or box cutter. Minimal sanding improved the look and it came out nice. I really like working with hard maple on the CNC router, it has a tight grain and does not splinter like oak and pine will when cutting small features
I took a picture of the sword of fire from the internet and used Solidworks to design a simplified version that would cut out nicely from wood. The Solidworks 2018 file is attached if interested.
