I saw a video-game knife trending on the downloads page and thought, what about a “real” knife? All research pointed to this KA-Bar 1220 Knife as a popular go-to knife. I downloaded @URPO's Solid 3D Model (not printable) because it looked the cleanest, and then spent a day thinking of the best way to create a shareable print/chopping it up/trying various joining options. I only altered one part of the knife - the handguard is “simpler” to make it easier to print, so it's really a 99% replica. There may/will be some strings on the upper lip of the grip overhangs. The handle prints standing up with a brim. The blade prints standing up using the handguard as its support.

This print requires five minutes of post-print assembly but is worth the patience. There is a 1mm inset area in the blade guard where the handle will sit. The more time you spend cleaning out this area/testing the fitment before gluing (don't break the guide stick!) the stronger and cleaner the final product will be. The handle only slots in this groove one-way, so if it doesn't line up spin the handle and it will. I used a razor to clear the hole, and metal files to smooth the flat area. The green highlighted area in the one picture is where I applied glue. All of the strength is basically in this this 1mm area. Using liquid super glue I put a line down the guide stick, flat part of handle, and flat part of blade (essentially all connection points). Insert the guide rail, spin it to spread the glue, and hold against the wall/floor or clamp for 60 seconds before playing with it. The final result is what I consider a 1:1 replica suitable for costumes, cosplay, or any other safe use.

KA-BAR USMC Knife by Urpo is licensed under Creative Commons