Tri Forged Studios

3D Printing - Casting - Mold Making - Production

 

Toronto Defiant Overwatch Replica Weapons (2022)

 
 

We were commissioned to create life-sized replicas of iconic Overwatch 1 & 2 weapons, finished in the Toronto Defiant team skins. This project combined custom 3D printing with refinished toy replicas, ensuring accuracy, durability, and fan interaction for photo ops.

Weapons built:

  • Junker Queen’s Jagged Blade Knife

  • Mercy’s Caduceus Staff

  • Genji’s Dragonblade Katana

  • Reaper’s Hellfire Shotguns

  • D.Va’s Light Gun

  • Tracer’s Pulse Pistols

  • Cassidy’s Peacemaker Revolver

Some builds began as pre-made NERF replicas that we reworked extensively. Screw holes, mold lines, and warning labels were sanded smooth, while 3D-printed components added accuracy. Some piece were primed, painted with a custom-mixed metallic red, detailed with custom vinyl decals, and sealed with a durable 2K automotive clear coat—ensuring a finish that was both safe and resilient for handling at events.

Other props, such as Mercy’s Caduceus Staff, were entirely 3D printed. The staff was sanded, painted, and assembled with opening side flaps to replicate the in-game design. Each weapon was carefully finished to balance authenticity and durability, bringing the Toronto Defiant’s in-game arsenal to life for fans.

Credits:

Artists: Alysun Pinsonneault, Riley Marini, Isaiah Cook, Ivan Cheung, Simran Mann, Andrew Mandaliti

Laser Cut Display Stands: Universal Recognition

Additional Laser Cut: ANP Cutting

Photography: Rachael Huibers