cutlass2.scad

// Playmobil Curved Sword — parametric OpenSCAD
// Based on hand sketch: curved blade (both edges), guard, rounded pommel
// Print flat on bed. Adjust handle_dia to fit Playmobil hand grip.

/* --- Tunable Parameters --- */

// Handle (must fit Playmobil C-clip hand)
handle_dia   = 3.5;   // mm — start here, test fit, adjust +/- 0.2
handle_len   = 12;     // mm

// Guard
guard_width  = 10;     // mm — total width of crossguard
guard_height = 3;      // mm — height along blade axis
guard_thick  = 3;      // mm — thickness (z)
guard_curve_up = 4;    // mm — how far the blade-side tip curves upward
guard_bar_dia = 2;     // mm — diameter of the guard bar

// Blade
blade_len    = 35;     // mm — from guard to tip
blade_width  = 8;      // mm — widest point near guard
blade_thick  = 2;      // mm — flat profile thickness (z)
blade_curve  = 6;      // mm — lateral curve offset at midpoint

// Pommel
pommel_dia   = 8;      // mm
pommel_thick = 6;      // mm

// Resolution
$fn = 64;

/* --- Modules --- */

// Curved blade profile — hull between cross-sections
module blade() {
    // Blade is a series of hulled elliptical cross-sections
    // from guard to tip, with lateral curve on both edges

    steps = 40;

    for (i = [0:steps-1]) {
        t0 = i / steps;
        t1 = (i + 1) / steps;

        hull() {
            blade_slice(t0);
            blade_slice(t1);
        }
    }
}

module blade_slice(t) {
    // t = 0 at guard, t = 1 at tip
    // Width tapers from blade_width to 0
    // X position curves using sine for the scimitar sweep

    y = guard_height/2 + t * blade_len;

    // Curve: sine sweep for scimitar shape
    x = blade_curve * sin(t * 120);

    // Width taper: starts at blade_width, narrows to point
    w = blade_width * (1 - pow(t, 0.8));

    // Thickness taper: slight taper toward tip
    th = blade_thick * (1 - 0.3 * pow(t, 1.5));

    translate([x, y, 0])
        scale([max(w, 0.3), 1, max(th, 0.4)])
            sphere(d=1);
}

// Guard — curved crossguard connected at both ends, blade-side curves up
module guard() {
    steps = 20;
    half_w = guard_width / 2;

    // Sweep a circle along a curved path from -half_w to +half_w
    for (i = [0:steps-1]) {
        t0 = i / steps;
        t1 = (i + 1) / steps;

        hull() {
            guard_point(t0);
            guard_point(t1);
        }
    }
}

module guard_point(t) {
    // t goes 0 to 1 across the guard width
    half_w = guard_width / 2;
    x = -half_w + t * guard_width;

    // D-shape: ends connect at blade/handle junction (y=0), center bows downward
    curve_factor = 4 * t * (1 - t);  // parabola: 0 at ends, 1 at center
    y_up = -guard_curve_up * curve_factor;  // 0 at ends, dips down at center

    translate([x, y_up, 0])
        sphere(d=guard_bar_dia);
}

// Handle — cylinder sized for Playmobil grip
module handle() {
    translate([0, -handle_len/2, 0])
        rotate([-90, 0, 0])
            cylinder(d=handle_dia, h=handle_len, center=false);
}

// Pommel — squashed sphere at bottom of handle
module pommel() {
    translate([0, -handle_len, 0])
        scale([pommel_dia, pommel_dia * 0.6, pommel_thick])
            sphere(d=1);
}

/* --- Assembly --- */

module sword() {
    color("silver") blade();
    translate([2.5,-5,0])
    rotate([0,0,90])
        color("gold")   guard();
    translate([0,-5,0])
        color("sienna") handle();
    translate([0,13,0])
        color("gold")   pommel();
    translate([0,1,0])
        color("gold")   pommel();
}

sword();

// Print info
echo(str("Total length: ~", handle_len + guard_height + blade_len + pommel_dia*0.3, " mm"));
echo(str("Handle diameter: ", handle_dia, " mm (adjust for Playmobil fit)"));
echo(str("Blade thickness: ", blade_thick, " mm (print flat on bed)"));