I work as a firefighter in my local town. One of my fellows asked me if I could design and print him an "awesome" custom ping pong paddle for the station. Of course I took on the challenge. I was inspired by Targ's baby rattle sword the most, and used his interlocking design for securing the blade and the pommel to the handle. The ping pong paddle design was taken from ScurtWad's paddle design. I had to custom make the handle to make it longer and more ergonomic for an adult's hand. It was a ton of fun to design and print.
I would recommend using a heat gun as a method of bonding the pieces together to make all the parts snug fit.
By the way, It works GREAT! This paddle brings awe and fear to those you face against in the fierce game of ping pong.
75% for Paddle 50% for rest
Orient the paddle with the blade facing upward. I used the "triangle" infill pattern in Cura for the paddle blade to replicate corrugated cardboard for strength. I ended up using a brim on all the pieces except the jewel and the pommel for extra support while printing.
Construction of your sword ping pong paddle
I used a heat gun to melt the ends of the handle piece and forced them into the groves at the paddle end and the hilt. This method gave me a very snug and strong bond between all the pieces. I used superglue on the jewel that goes into the pommel.
Happy paddling :D