Conor Mulligan - Engineering Portfolio
Create Your First Project
Start adding your projects to your portfolio. Click on "Manage Projects" to get started
Bloodborne Saw Cleaver
Description
"A trick weapon fashioned in the workshop of the Healing Church, designed to hunt beasts with ruthless efficiency."
The Saw Cleaver is one of the most iconic and feared weapons wielded by Hunters in Bloodborne, embodying the brutal and unrelenting nature of the Hunt. Forged for the express purpose of slaying the horrific beasts that plague Yharnam, this trick weapon seamlessly transitions between two distinct forms: a compact, swift cleaver for rapid strikes, and an extended, scythe-like blade for devastating long-range attacks.
Favored by Hunters for its versatility and lethality, the Saw Cleaver is designed to tear through the grotesque flesh of Yharnam's cursed creatures with serrated edges that deal extra damage to beasts. Its unique transformation mechanism allows it to switch modes mid-combat, adapting to the unpredictable horrors that lurk in the shadows. In its folded state, it excels at swift, close-quarters combat, while its extended form grants greater reach and momentum to cleave through multiple foes at once.
Dripping with the blood of countless horrors, the Saw Cleaver is more than just a tool—it is a testament to the grim determination of Hunters who walk the night, facing death and madness with every swing. Whether striking down towering monstrosities or battling the insidious affliction that consumes the city, the Saw Cleaver remains an essential companion for those brave enough to embrace the Hunt.
Challenges
- Developing a functional hinge mechanism that allowed the blade to fold securely without compromising the visual design.
- Achieving a realistic, battle-worn aesthetic for the blade and handle.
Results
- Created an accurate, visually striking replica of the Bloodborne Saw Cleaver with a functional folding mechanism.
- The combination of distressed wood, weathered metal, and bloodstained fabric captures the essence of the in-game weapon.
Engineering Skills Demonstrated
- Material Fabrication: Used HDPE and ABS for structural and functional parts.
- Mechanical Assembly: Designed a locking hinge mechanism with removable pins for durability.
- Painting and Weathering: Simulated aged metal using metallic paints and acrylic washes.
- Thermoforming: Shaped ABS for functional and decorative components.
Project Summary:
- Created an intricate, folding replica of the Bloodborne Saw Cleaver, combining woodworking, thermoforming, and ABS plastic construction with realistic weathering techniques to replicate the worn, bloodied aesthetic of the in-game weapon.
Design and Fabrication Steps:
[1] Blade and Hinge Mechanism:
- Modified a pattern from JJubsCosplay on Etsy, using 1/2-inch HDPE plastic for the blade and 1/4-inch and 1/2-inch ABS plastic for the hinge components.
- Shaped the blade teeth with a DeWalt angle grinder and flap disk, while thermoforming 1/8-inch ABS plastic to create the handle of the locking mechanism.
- Constructed the hinge mechanism with Chicago screws for easy disassembly and incorporated a spring clamp and steel pins for functionality.
[2] Handle Construction:
- Modified a fire axe replacement handle from Home Depot to fit the hinge mechanism, shaping it with a hacksaw and angle grinder.
- Burned the wood with a blowtorch for a distressed finish, followed by sanding and sealing with boiled linseed oil.
- Reinforced the handle with ABS brackets, riveted and glued for durability.
[3] Weathering and Painting:
- Painted ABS and HDPE components with TAMIYA gloss black lacquer, followed by a dry-brushed layer of FolkArt Metallic Gunmetal Gray and silver.
- Applied a black and brown acrylic wash for realistic aging effects, wiped off after settling into cracks and crevices.
- Weathered 1.5-inch linen ribbon by soaking it in coffee and dirt, followed by a wash of dark red and black acrylic paints to simulate bloodstains.
