It all started when a friend asked if I could make these, Kitana’s fan blades from Mortal Kombat 9. Challenge accepted!! Below is the reference photo I used to make the fans.
Started with the blades, I wanted to create a 3D model in order to duplicate easily. Using Sketchup, I made the model then chopped the model in half because it wouldn’t fit in my printer build space. Each blade is measured out to 14 inches.
Original photo, 3D model, Printed part 
3D printed part 
Comparison with a paper template
Moving onto the design, I had to print a couple copies to test the folding techniques and the final look to the folds.
1: Design pattern 
2: Color comparison of different versions 
3: Folding tests
Gluing: using a combination of double-sided tape and ABS cement, I glued the blades and pattern together. The double-sided tape alone would have been good enough. I just wanted to use the glue/cement just in case since I already had it.
1:Layout and positioning 
2: Taped and cut out papers 
3: Aligning the blades one last time 
4: Double-Sided tape 
5: Glued and taped
Finished version of 2014. After completing this task, I felt like I needed to take it to the next level…
Unfolded finished version 
@echothreesixty
Remake: I used the same 3D model in order to cut it on the CNC machine (positive mold). I poured casting silicone into the positive mold and created a negative mold. With the negative, I was able to cast a positive part and duplicate easily in one piece.
Delrin mold made on the CNC machine 
Resin casting 
Resin cast parts 
Hardware: 1/4″ binding posts
Final 2014 Anime Expo photo shoots.
PC: jayjayn.com
Model: @echothreesixty
PC: jayjayn.com
Model: @echothreesixty
Anime Expo 2014
