Building a 3D Printed Aumban Pulse Rifle

Combining 3D printing, PVC pipe, tension springs and traditional hardware to create an impressive display prop inspired by the new Mandalorian & Grogu film.

As a huge fan of both Star Wars and prop building, I wanted to challenge myself with a larger, more advanced project than my usual prints. This AMSR Pulse Rifle build has quickly become one of the most ambitious projects I've taken on, not simply because of its size, but because it moves beyond being "just another 3D print".

This project combines multiple manufacturing techniques, requiring a mixture of 3D printed parts, PVC pipe, tension springs, compression springs and mechanical assembly to create a prop that is both visually impressive and mechanically satisfying.

Why this project is different

Many people assume large props can simply be printed, glued together and painted. While that approach works for some display pieces, this build requires a lot more engineering behind the scenes.

The AMSR Pulse Rifle is made up of multiple sections that need to remain:

• Lightweight

• Strong and durable

• Straight and aligned

• Capable of supporting moving components

• Easy to disassemble for maintenance if required

To achieve this, I've incorporated a variety of materials rather than relying solely on plastic.

The materials being used

3D Printed Components

The majority of the visible sections are being produced using my 3D printers.

These include:

• Stock assembly

• Receiver housing

• Barrel shrouds

• Front fork assembly

• Mechanical details

• Decorative panels

• Internal brackets and supports

3D printing allows incredible levels of detail that would otherwise be difficult and expensive to achieve using traditional methods.

However, large prints still require reinforcement.

PVC Pipe Reinforcement

The rifle's central spine is being strengthened using PVC pipe.

This serves several purposes:

• Prevents sagging over time

• Maintains overall alignment

• Adds structural rigidity

• Reduces stress on glued joints

• Allows large sections to remain lightweight

PVC is an excellent material for prop building because it's inexpensive, easy to source and surprisingly strong.

It also allows multiple printed sections to slide over a single rigid core.

Tension Springs

One of the more interesting aspects of this build is the use of tension springs.

These are being used to create realistic movement within certain sections of the rifle.

Benefits include:

• Smooth mechanical action

• Consistent return movement

• Greater realism

• Reduced wear compared to relying on plastic flexing

Incorporating springs into a prop build elevates it from being a static display piece into something that feels engineered.

Compression Springs

Compression springs are also being used throughout the build.

These help replicate the feel of moving components whilst preventing unnecessary strain on the printed parts.

Their uses include:

• Supporting moving mechanisms

• Creating tactile feedback

• Improving functionality

• Increasing durability

Designing around spring tolerances is often one of the most time-consuming parts of a project.

Too much tension can damage parts.

Too little tension can make mechanisms unreliable.

Finding that balance is part of the fun.

Planning before printing

Projects of this size require significant preparation before committing to final assembly.

Some of the considerations include:

Print Orientation

Every component has to be oriented correctly to maximise strength.

Printing in the wrong orientation can create weak points that may eventually crack.

Tolerances

Parts that interact mechanically need clearance.

This means accounting for:

• Material expansion

• Printer accuracy

• Paint thickness

• Assembly movement

Sometimes a fraction of a millimetre can make all the difference.

Weight Distribution

Because this is a long prop, weight management is extremely important.

Adding too much weight at the front can make handling awkward and put excessive stress on joints.

Using PVC internally allows strength without making the rifle unnecessarily heavy.

The assembly process

The build is currently being assembled in stages.

Stage 1: Printing all major components

Each individual section is printed separately.

This reduces print failures and makes replacing parts much easier if needed.

Stage 2: Internal reinforcement

PVC pipe is installed to create a rigid backbone throughout the rifle.

Stage 3: Mechanical installation

Tension and compression springs are installed and tested.

This stage requires multiple adjustments to achieve smooth operation.

Stage 4: Dry fitting

Every component is assembled without permanent adhesives first.

This ensures:

• Correct alignment

• Proper fitment

• Functional movement

• Easy troubleshooting

Stage 5: Final assembly

Once everything has been tested:

• Components are secured.

• Seams are refined.

• Gaps are filled.

• Surface imperfections are removed.

Stage 6: Painting and weathering

The final stage will bring the entire project to life.

This will include:

• Priming

• Base coating

• Detail painting

• Metallic accents

• Weathering effects

• Battle damage

The goal is to create a prop that looks as though it has come straight from the Star Wars universe.

Challenges along the way

Projects like this rarely go perfectly first time.

Some of the biggest challenges include:

• Aligning long sections accurately

• Adjusting spring tension

• Preventing barrel flex

• Managing print tolerances

• Hiding seams between large pieces

Problem solving is a huge part of prop making and often becomes the most rewarding aspect of the entire process.

Why I enjoy projects like this

Projects like the AMSR Pulse Rifle perfectly demonstrate why I love 3D printing.

It's not simply about pressing "print".

It's about combining multiple skills together:

• Engineering

• Design

• Mechanical problem solving

• Traditional model making

• Painting

• Finishing techniques

Every project teaches something new.

Every challenge improves future builds.

And seeing individual pieces gradually transform into a full-sized prop never gets old.

Important Disclaimer

This is a fan-made display prop inspired by material from the Star Wars universe and is intended for cosplay, display and collection purposes only.

This is not a functional weapon, cannot be converted into one and is not designed for any practical use outside of display and costuming.

Please always follow local laws and regulations regarding the transportation and public display of prop replicas.

Never carry prop items in public without appropriate packaging or permission from event organisers.

Follow the Build

I'll be documenting the entire process as the project progresses, including:

• Printing updates

• Assembly stages

• Mechanical testing

• Paint progress

• Finished reveal photos

If you're interested in large-scale prop making, 3D printing and behind-the-scenes engineering, keep checking back for future updates as this AMSR Pulse Rifle comes together piece by piece.