Ezio’s Sword — Assassin’s Creed Series

Past Work Showcase

This piece is our recreation of Ezio’s Sword from the Assassin’s Creed series.

Although the finished design may look relatively straightforward at first glance, this project actually went through three major iterations before we arrived at the final version shown here.

Most of the challenges came from the printing structure.

The guard has a particularly complex shape, and the connection between the guard and the grip leaves very little surface area for reinforcement. Finding a solution that could maintain both the original proportions and sufficient structural strength turned out to be one of the most difficult parts of the project.

Version 1 — Segmented PETG Printing

For the first version, we used a segmented PETG printing structure.

The individual sections printed well, but the contact area between the guard and the grip was simply too small. There was very little surface available for bonding and structural support.

The sword initially appeared secure after assembly, but during international transportation, the guard eventually separated before or after reaching the customer.

That failure made it clear that simply improving the adhesive would not be enough — the printing and assembly structure itself needed to be redesigned.

Version 2 — Single-Piece PETG Printing

For the second version, we changed the design to a single-piece PETG print.

Because of the length and geometry of the sword, we used an experimental infinite-Z belt-style 3D printer to produce the main structure as one continuous piece.

This solved the structural problem. Without the previous joint between the guard and grip, the overall construction became significantly more reliable.

However, it introduced another issue: print quality.

The experimental printing method was suitable for producing unusually long parts, but the surface resolution and overall level of detail were not good enough for the standard we wanted to achieve.

Structurally, Version 2 worked.

Visually, we still felt there was room to improve.

Version 3 — The Final Version

The sword shown in the photos is our third and final iteration.

For this version, we moved away from PETG and produced the main structure as a single-piece SLA resin print.

SLA printing allowed us to preserve the complicated geometry of the guard while achieving a much finer surface finish. Surface details can be reproduced at approximately 0.3 mm resolution, making the typical layer lines associated with FDM printing extremely difficult to notice on the finished piece.

More importantly, we were able to achieve this improvement in surface quality without sacrificing the structural stability that we had solved in the second version.

The result is a piece that combines:

• A more reliable one-piece structure
• Much finer surface detail
• Significantly reduced visible print lines
• Better reproduction of the original guard geometry
• Sufficient overall structural strength for a full-size display replica

Three Iterations, One Final Design

This project is a good example of how our replicas often evolve behind the scenes.

Sometimes reproducing the appearance of an in-game weapon is only the beginning. Turning that design into a physical object also means solving problems involving printing orientation, joint strength, materials, assembly, transportation, surface finishing, and long-term structural stability.

Ezio’s Sword took three major versions before we reached the result shown here.

Each version taught us something, and the final piece would not have been possible without the problems — and failures — we encountered along the way.