Other Projects

Stormbreaker Axe

Oct 2025 - present

CAD · Structural Design · Metalworking · Welding · Heat Treating

My brother and I are building a working replica of Thor's Stormbreaker axe from Marvel.

Problem: The design has to balance movie accuracy against usability: the axe needs to be large enough to look like the movie prop, light enough to hold, and strong enough to absorb the impact of regular axe use.

Load path: Instead of relying on the outer shell for strength, impact loads go through an internal skeleton: a cross shape made from 1/4" steel. The outer shell is thin sheet metal, since it doesn't have to carry those loads.

Weight budget: Holes are cut out of the skeleton wherever it isn't load-bearing, and the thin shell keeps the rest of the weight down. Overall the axe is 13 inches long and roughly 10 lbs.

Edge retention: The tip is the same mild steel as the rest of the skeleton, which is too soft to hold an edge for long, so we heat treated it to increase its hardness.

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