Up-date;
Had a meeting with Jet3D this week, great guy, full of enthusiasm and keen to use his skills to bring this project together.
We have established the basics for the hilt and are now working on producing a prototype, when we have this we can explore the options on manufacture.
Jet3D has explained the available processes and will be using his contacts to find the best way forwards.
There are some exciting techniques that we can use that may not be as expensive as first thought :))
More soon...