Gaffi Stick - Cosplay Battle Staff

Authentic Prototype v1.1 Design

UPDATE V1.5 - 2/3/26

See Updates Document Attached At bottom of page for more information.

This Update includes: 

A thicker tube casing for the Carbon Fiber Rod

Increased Thickness size of Top Weapon

Slight differences in tolerances (Accounting for filament expansion)

Updates document attached to MakerWorld

Gaffi Staff – Reinforced Modular Design

By Layerline Australia

Inspired by the iconic desert warrior aesthetic of the Tusken Raider gaffi stick from Star Wars, this is an original Layerline Australia design built with strength, modularity, and durability in mind.

This staff blends sci-fi inspiration with practical engineering to create a sturdy and display-ready prop that feels solid in hand while remaining lightweight.

Reinforced Internal Structure (Optional)

To ensure durability and rigidity, this builds features:

• 500 x 8mm carbon fiber rod core reinforcement (Can be substituted for 3DP rods)
• 1x M4x6x6 heat-set insert (For Glueless Assembly)
• 1x short M4 screw for secure assembly (For Glueless Assembly)

The carbon fiber spine dramatically increases structural strength while keeping weight down, making this far more robust than a standard printed prop.

Material Choices for Maximum Durability

For best results, the following materials were used:

• Polycarbonate (PC) – for the weapon head components
  • High impact resistance
  • Strong layer adhesion
  • Excellent durability
• PETG – for the rod casing surrounding the carbon fiber
  • Tough and slightly flexible
  • Great balance between strength and printability

This combination creates a reinforced, impact-resistant build designed for long-term use and display.

Modular Design

The staff is fully modular.
Future attachment options can be added, allowing different head designs and configurations to be swapped onto the reinforced core system.

This makes the design expandable and adaptable as new variants are released.

⚠️ Important Notes

• This is inspired by Star Wars, but it is an original design by Layerline Australia.
• This prop is intended for display, cosplay, and collection purposes only.
• It is not intended to be used to harm people or animals.