Skeletonized M3 Balisong

I wanted a printable M3 balisong that flips pretty well and uses the M3 hardware I have on hand, so I made it! Demo here: 

Printed in California Filaments Cloudy White PETG and Overture Cream Light Blue PLA(now removed). 

Parts

The needed hardware is as follows(all but the pivot hardware is optional):

• Heat-Set Inserts:
  • Option A:
    • 2x M3x6mm Heat-Set Inserts(Handle Ends)
    • 2x M3x4mm Heat-Set Inserts(Pivots)
  • Option B:
    • 4x M3x4mm Heat-Set Inserts(Pivots and Handle Ends)
• M3x8mm/M3x10mm Socket-Cap Screw(Pivots)
• M3x6mm Socket-Cap Screw(Handle Ends)
• 3x 6x3mm Neodymium Magnets(Blade)

The parts to print are as follows(for the normal model):

• 1x Blade
• 1x Safe Handle
• 1x Bite Handle
• 2x Bushings(any spec, 7.8x4.25mm works for me)

There are several blades in the Blender project. They are not all finished to the same degree of quality, as I really only like the blades inspired by the Fellowship Blades Medusa/Medusa Trainer, but you're free to modify anything as you see fit.

Printing

I get pretty good results using the OrcaSlicer default 0.16mm profile, but with the following settings changed: 

Quality

• Seam gap: 2%
• Wipe on loops: ✓
• Precise wall(experimental): ✓
• Bridge/Internal Bridge flow ratio: 0.95
• Thick bridges: ✓

Strength

• Top/bottom shell layers: 50-60(or 100% infill, you just want completely solid parts.)

Supports

• Normal supports(Snug style)
• Threshold angle: 40°
• First layer expansion: 1mm
• Build plate only: ✓
• Top/Bottom Z distance: 0.05mm
• Support/object XY distance: 0.1mm

I print the blade and bushings at 0.08mm layer height, and ensure the edge of the blade is supported not to prevent droop, but to prevent it curling up.

With those settings, I do not have supports for the skeletonized part of the handle, only the pivot semicircle. 

Tuning

It is very possible that the bushings do not fit. In that case, you can model your own(the blade hole is 8x4mm), or use the procedural bushing in the Blender project. 

Select the bushing, set the values as you please…

…then export it. “Selection Only” ensures that only the bushing is exported, as Blender will export every scene item by default. 

It's kinda scuffed, but here's a quick video for the assembly:

As for the license, do literally whatever you want. Remix, sell, all of it(after I reopen it after the Nabalis design thing).

If you have any questions, ask in the comments and I'll update this with more instructions as needed. 

Other Parts

There is a version of this model that is ultralight and features no metal. For that, print all the files in the corresponding folder, and hammer the pins into place. 

The Bladeless Version

There's also a version of this model that has no blade. I made it so I could flip something at school. You could probably also get it through TSA. 

For that model, the BOM is the same as the normal balisong, minus the magnets. 

Printing

Print the corresponding parts. If you print both the A and B handles, you'll have a perfect mirror. If you print two of the same one, you can put the heat set inserts on opposite sides.

Use the same bushings, as the pivot mechanism is identical. Note: the handles will need support on the inside.