Hey folks! Stand by for a cool update regarding this MoMma, complete with PICS!! I'll be editing this post...
Okay, so, Bryan and Adam were gracious enough to allow me to print a couple prototypes from their models of this hilt. I printed one on the Photon, in regular grey resin, and the other on the Prusa MK2S, in PLA.
The model is beautiful. Even when looking at it on the monitor, it's easy to see how correct this thing is, and how right it "feels". I can't compliment them, or Dan (Anakin Starkiller) enough, for the effort and the work they collectively put into getting this thing right.
A few details have actually changed, since I finished these prototypes. Mostly in the pommel area (and I believe a bit at the emitter end, as well). I actually slightly modified the pommel end cap on the resin version (the one in the pics that does NOT have the arrows, or the tri-ring), by turning the diameter down a little less than .5mm. This gives a little more of a step up to the cubes, or "gear" section.
And actually, I had to do a little cleanup work on both printed hilts, so the small, round "divot", just below the emitter flange was unfortunately lost on both prototypes. I'd say, on average, the amount of material lost in diameter is no more than .3mm per side. And less cleanup was needed on the majority of the resin parts, as the surface finish out of the printer is cleaner and more crisp. Still, I'm learning with the Photon, and likely didn't print the parts in their optimum orientation. Some parts came out with the slightest amount of warpage, but I was able to fix that on the lathe.
Basically, I'm taking the long-winded route in saying that the machined aluminum parts will be even more beautiful than these prints (if that wasn't already obvious). Details will be more crisp, etc. One thing to note, is the bevel at the underside of the control box. It's a little more pronounced on the PLA version, since it was printed right side up on the plate, so for a better idea of what that will look like, refer closer to the resin print (again, the one with NO arrows in the control box, and NO tri-ring).
One of the reasons for printing these prototypes was to test the brilliant control box design. There's an outer box, with what will be a copper "canoe" or "sled" section that slips into the box, and over the "plungers" of the black buttons. The back side of the buttons have stems, or "plungers" that will make contact with the tactile switches, and the buttons are also spring-loaded against the outside of the box, to avoid phantom clicks, or presses. The canoe also locks the buttons in, once it's installed in the box. It's a really cool design, and it works great! It's really satisfying to push these buttons!
There are several other REALLY cool design features that I didn't mention, you'll have have to wait for those to be revealed!
You'll notice Bryan's newest custom circuit card in the PLA version, complete with "conformal coating" details at the edges! And in the resin version, I've fitted a Slothfurnace card. I'm including pics of the prototypes alongside an AS V2 "Builder's Kit", and my personal uber-modified old Rylo Hero, for comparison's sake.
It has certainly taken some getting-used-to, holding this hilt in front of my eyes! For all these years, the Hero prop has been made too small, in varying degrees, likely because folks had based measurements on the resin castings of the real prop, not taking shrinkage into account, or not taking ENOUGH shrinkage into account! Still, there are of course many beautiful iterations of this prop out there. But I feel that with this replica, Bryan (Brrogers) and Adam (Verity Cosplay) and 7 Chambers and Dan (Anakin Starkiller) have FINALLY made the MoM of all Heroes! I think it's safe to say that all you folks who weren't happy with the first "Ultimate" Hero, will be MORE than happy with this!
Thank you guys, for allowing me to help, and to be a small part of this project. I absolutely cannot wait to see this thing in metal!
I'll now shut it, and let the pics do the rest!
Here's a link to the album. There's LOTS more pics, there.