Finishing and assembly: bringing your 3D printed replicas to life

A 3D printed replica truly comes into its own once it's properly finished and assembled. Here's a guide to ensure each piece you produce becomes a believable, sturdy, and impressive cosplay weapon.

1. Sanding and Preparation

Before assembly, each part must be carefully sanded.

· Hand sanding or using an orbital sander (120 → 220 → 400 grit)

· Pay particular attention to the contact areas between the parts for a precise fit.

· Clean with isopropyl alcohol to remove dust and residue.

2. Dry Fit

Before gluing anything:

· Assemble all parts without glue to test the fit.

· Identify areas that require rework (file, cutter, or additional sanding).

· Discreetly mark the assembly order with a pencil.

3. Final Bonding

Once the dry assembly is approved:

· Use a cyanoacrylate (super glue) or 2-part epoxy for maximum strength.

· Apply a thin layer, pressing the pieces together for a few seconds.

· For large surfaces, consider using soft clamps or tape while drying.

4. Filling and Bonding

Fill any visible joints or small defects:

· Use a plastic or wood filler.

· Apply with your finger or a thin spatula.

· Once dry, sand gently with 400 grit for a smooth finish.

5. Priming and Painting (summary)

· Apply a spray primer (gray or black)

· Base coat: matte black, metallic, camouflage, etc.

· Effects: dry brush, wash, scratches.

· Matte or satin varnish for protection.

6. Details and Additions

· Add dummy screws, cables, stickers, LEDs, or magnetic parts for added realism.

· Integrate moving parts (removable magazine, flexible trigger) if the model allows.

7. Transport and Display

· Protect your replica with a cover or foam case.

· Avoid thermal shock (exposure to sunlight, driving in the car in summer).

· For exhibitions or conventions, provide a discreet but stable support.

With care and precision, the finishing stage transforms your raw 3D prints into stunningly realistic replicas.

Take your time: every detail contributes to the illusion.

Doom Shotgun "The Dark Age" - Original Version