F44AA Pulse Rifle from Alien: Romulus

Update: 03/29 - Added a simple wall mount. Supports at back of the barrel grip and under the trigger guard. I designed it to use as little material as possible while still looking somewhat in universe. Prop will rest against wall, be warned if that is a problem.

Update: 03/23 - Added a safety plug for the barrel. Required at a lot of comic con style conventions and cosplay. It screws into the rifling grooves of the barrel. Made it loose enough to not damage paint. Small bit of removable adhesive like hot glue at the barrel tip keeps it in place. I printed mine in a bright orange tpu. Stayed on all day at a convention.

Update: 10/18 - Added a small chamfer to the rear mount point for the rifle sling swivel. Turns out the swings have an angled bit that I missed. If anyone printed the old one, small bit of sanding will ensure it moves freely.

Update: I have moved this out of work of progress since I have done all the printing and assembly on it. I have also uploaded a svg of the markings for those with vinyl cutters.

This is an early release. I have been printing parts and prototyping this for the past month since seeing the movie. I am fairly confident of it at this point for release.

Fair warning: there is a lot parts that need printed for this build. I did this for many reasons: I think it's more rewarding to have something that is assembled like a real object, I was able to hide any potential seam lines much more easily, makes painting easier since colors can be group, etc.

Use the 3mf so that you do not have position all the parts yourself.

I hope most parts of the assembly will be fairly straight forward but I do realize that I have some bias. The instructions at this point are a bit limited. I have included the step file for the model to help viewing final assembly.

Needed Hardware:
-2 3x60mm rods for stock "wings" (Shorter works as well)
-m3 pan head screws <15mm long. You will need some very short ones for a few places like the very bottom of the grip.
-6mm locking on/off switch (for reference: https://www.amazon.com/gp/product/B07DWS195R/). Momentary is fine if you aren't planning for lights.
-2 6x30mm springs
-1 3x20mm rod for trigger
-3 6x150mm dowel rods for stronger stock (1/4" is very close to this size)

All screw holes are made for m3 pan head screw. Other screws can be used those are just the ones that I thought looked the most like the real prop. They are cut at a depth of 15mm but shorter screws can be used in many areas this was done for flexibility. I have included a lot of alignments tools that I have marked as "joiners" they are to help join/align parts together while gluing. A 1/2" dowel rod can be inserted through the barrel hole to help with the rigidity of the model. I chose 1/2" since where I live that is the easiest size to the find in any store. It is actually cut to 12.9mm so it will be very close to 13mm.

The handles are very long and have been cut into 220mm sections for easier printing. They will need post processing and gluing. There are pegs included to help with alignment. There are inside "bump" parts that print separately so that can be printed flat on the bed. Adhesion is critical and brims are strongly suggested.

The stock is made up of 3 arms which I currently prefer the solid arm version. There is a version with pegs for alignment while gluing and another that is hollowed out for a 6mmx150mm rod for rigidity. There are covers for the arms that print separately.

The rear of the stock has a non moving outer portion and center that rotates 90degrees. I have included a rotation limiter. Refer to the last picture for the proper position during assembly. A double headed hex bolt is used to keep it in place with threaded cap screws on both ends. The hole may need cleaning with sand paper since I have kept it very tight to maintain the rotation limit.