Brutus: A Tactical Nerf/Airsoft Toy Knife With Locking Sheath

Et tu, Brute?

Brutus is a a tactical play knife that is the perfect accessory to your battle belt!

Featuring a large, knurled handle for adult hands, satisfying locking sheath, and belt attachment points, Brutus is your go-to quick-draw toy melee weapon whenever the opposition gets too close for comfort.

Hardware Required:

• Glue (PVA or other)
• 5x M3x12 socket head screws for the front (it will accept M3x8 all the way to M3x16, but I used M3x12 for mine)
• 4x M3x8 pan head or low profile screws for the back (socket head screws will also work, but may stick out too far for your own personal comfort).

Prints Needed:

TPU or other flexible filament:

• 1x Brutus_Knife_Blade (I wouldn't go higher than 15% infill to maintain a sufficiently pliable blade)
• 1x Brutus_Long_Buckle or Brutus_Short_Buckle (short buckle was the original, but I found that the long one worked way better on a belt, you can also design your own attachment point using the provided original design files)

PETG or other non-brittle filament:

• 1x Brutus_Sheath_Middle (this is the actual compliant mechanism that locks the blade in, PLA would also probably work, but I haven't tested it)

Any non-flexible filament:

• 1x Brutus_Sheath_Back
• 1x Brutus_Sheath_Top
• 3x Brutus_Pin
• 2x Brutus_Handle_Scale

Assembly Instructions:

The Knife:

1. Insert all three pins into the knife blade.
2. Apply glue to the flat sides of both handle scales.
3. Fit both handle scales together onto the knife blade, clamp gently until glue dries, wipe away excess while it's wet.

The Sheath:

1. Stack together sheath back, sheath middle, and sheath top, making sure that the rectangular divot in sheath back is facing away from the assembly.
2. Hold the stack together tightly and insert the M3x12 socket head screws into the front holes.
3. Flip assembly over.
4. Interface flexible buckle piece into rectangular divot.
5. Insert the M3x8 pan head screws and tighten. You may have to push hard to deform the flexible buckle piece while tightening the screws.

Your sheath and knife should now be assembled! You should now check the fitment, and loosen or tighten the front screws if the level of friction is not how you like. Enjoy!

Conclusion:

Enjoy playing with or fidgeting with Brutus! Remember if you plan on playing with others to print the blade with a flexible filament.

If printing for the intention of playing with others, make sure all parties consent to such a toy being used. A TPU ‘knife’ might not be dangerous, but it still can hurt.

I release all my models under Creative Commons Attribution, but if you find my models helpful, feel free to tip me here: https://ko-fi.com/derpynate