cosEver try to pack your cosplay weapon or prop for a convention, only to realize it’s longer than your suitcase? You just spent 40 hours 3D printing your legendary axe, and now you’re trying to figure out how to get it to Comic-Con without breaking it—or paying for an extra checked bag.
Today, we’re fixing that problem once and for all. I’m going to show you how to design and 3D print cosplay props that screw together, so you can assemble them at your destination and still look like you just stepped out of a boss battle.
The Real Battle: Traveling with Cosplay Gear
Big props are awesome—until you have to travel with them. Whether it’s a giant axe, a sword, or a staff taller than you are, getting it safely to your event is always a challenge. The solution? Modular design.
By designing your props to break down into smaller pieces that screw together, you can fit everything neatly into your suitcase and reassemble it at your destination—no broken parts, no awkward stares from TSA.
Step 1: Designing the Threads in Tinkercad
Let’s start simple. Open up Tinkercad, and search for a basic thread shape. Drop it onto your build plate and adjust the diameter to about 30 mm—you want it to have a little heft when you screw it into your 3D print.
Now increase the number of rotations to 10, and set the height of the thread to roughly two inches. This will be your male thread—the part that sticks out.
Duplicate it and resize the diameter to 32 mm to create the female thread—the part it screws into. These two should fit together snugly once printed. Trust me, I’ve done this a lot, and this size combo works really well.
🧰 Free STL Files of Threads → https://makerbuildit.com/products/30-and-32-mm-threads
When you’re happy with the fit, export both parts and send them over to Nomad Sculpt.
Step 2: Building the Prop in Nomad Sculpt
Now comes the fun part—designing your actual cosplay piece. I’m going with a simple axe for this tutorial, but you can use the same technique for any prop.
Import your threads (both large and small) into Nomad Sculpt. They’ll probably come in pretty big, so check your measurements and resize them down to around 304 mm. Once that’s done, duplicate your main shaft and move it upward to create the top spike of the axe.
To make everything one solid model, select all the parts and perform a voxel remesh. This merges everything cleanly and ensures your screw joints will work once printed.
Step 3: Adding the Top and Bottom Connections
With your axe body modeled, it’s time to add connection points. Import your smaller thread again, line it up, and clone it. Move one to the bottom and one to the top of your handle. Then voxel remesh them with your main body.
Now, both ends of your axe can screw together perfectly once printed. No glue, no guessing—just solid, modular design.
Once you’ve got that done, you can export it and bring it into your slicer for final prep.
Step 4: Printing and Assembling
After printing your parts, it’s time for the big moment—assembly. Screw the sections together and make sure everything lines up. It should feel sturdy, almost like a real threaded handle.
For the axe I made, the bottom handle and blade sections connect with satisfying precision. I added a stone texture for extra realism, and it actually looks like something straight out of a fantasy game.
Pro tip: Apply your texture after boring the holes for your threads—this ensures the fit isn’t distorted.
The Final Build
And there you have it—an axe that breaks down into pieces, fits in your suitcase, and reassembles on-site. It’s strong, travel-friendly, and won’t draw any weird looks at airport security.
Creativity doesn’t need a workshop or a warehouse—it just needs an idea and a printer. So wherever you go, keep making, keep building, and prove that your imagination packs light.
🔧 Resources & Links
🔩 TinkerCad → https://www.tinkercad.com/
🗿 NomadSculpt → https://nomadsculpt.com/
🛒 Filament Used:
Anycubic PLA Gray → https://amzn.to/4qgOxMM
Anycubic PLA Black → https://amzn.to/43oQGMu
Anycubic PLA Tropical Turquoise - https://amzn.to/4ot6czi