Children's "Ninja Sword" (Katana Tsuka & Tsuba)

thingiverse

The default scale is designed for a child, but can be scaled up for an adult. The tsuba (hand guard) and tsuka (handle) were designed in Fusion 360. The tsuka mates into the circular recess on the bottom of the tsuba. There's also a 9mm hole running through the tsuba and tsuka to accommodate a rod to run through an EVA foam blade to maintain rigidity throughout. The rectangular channel on top of the Tsuba is designed to have the EVA foam blade rest inside. The tsuka can be wrapped in cord or rope to imitate the distinctive diamond pattern.