WarFairy Charon 3D Printed AR15 Lower

Remember the WarFairy 3D printable AR lowers we posted a while ago? (You can see themย here and here). Well it looks like someone actually made one, and test fired it too. It didn’t go too smoothly however, check out the creators notes and video below.


These pictures show my 3D printed AR15 lower which I plan to test out this evening. I started with the WarFairy Charon design, and made my own modifications (different/larger buttpad for my desired length of pull, beefed up front takedown pin area and bolt release pin area), and printed it out of ABS using my XYZPrinters Da Vinci 1.0 consuming approximately 1 spool of 600g. I plan to do the first test fire tonight, fingers crossed! And yes, this is entirely legal for me to make / possess where I am, and this firearm conforms to all ATF rules like any other AR15 lower.

UPDATE: Trying to get the buffer tube opened up (it was binding when I ran the charging handle by hand) I must have just thumped it or pushed it wrong, and I split it in half through the trigger pin. And out here at my relative’s house where I was planning to shoot, apparently there is no Acetone around, so I will have to glue it back together at home tonight and try to test it tomorrow. http://i.imgur.com/IfiQcnc.jpg

UPDATE 2: I have things gluing back together now, and hopefully I will get to take a shot with it tomorrow evening. Here is a picture of the 3D printed Lower (red) with the Upper I intend to run on it, lined up with a purchased AR15 (black) which has a bumpfire stock mounted on it, which I 3D printed too. And a banana for scale. http://i.imgur.com/fFCbBpQ.jpg

Much information about this can be found in my previous thread based on my image gallery of this: http://www.reddit.com/r/guns/comments/2klpes/my_3d_printed_warfairy_charon_variant_ar15_which/

I figured it needed a new thread for this video. It still has some issues with failure to feed due to drag in the buffer tube, and after six shots it split vertically through the rear takedown pin as shown here: http://i.imgur.com/0ajipfx.jpg But, being 3D printed ABS, I believe I can just get some acetone down into that split and have it re-bond successfully. However, I may retire this one to be a wall trophy as my first 3D printed firearm, and focus on redesigning and printing a new and improved one instead of continuing to re-bond this one every time it breaks.



Ray I.

Long time gun enthusiast, archery noob, Mazda fan, Sci-Fi nerd, Whiskey drinker, online marketer and blogger. My daily firearms musings can be found over at my gun blog ArmoryBlog.com and Instagram.

Shoot me an email at ray.i@staff.thefirearmblog.com


  • USMC03Vet

    Somebody hurry up and start up the Tediore Corp already.

    They know how to print gunz.

    • Matt Shermer

      Not to mention the grenade attribute…

    • SM



  • Blake

    Think I’d be using some heavy-duty gloves in addition to the face shield…

  • iksnilol

    Glad he put a banana for scale, otherwise I would have had no idea how big it is.

    • BryanS

      And that he used a grade 1 standard size banana.

      • iowaclass

        Let’s call it a “banana clip” and get everybody real mad.

      • iksnilol

        Yeah, I really hate it when people use a non standard size scale. Really messes with your perception.

        • MR

          Not sure how to spell it, but I’m thinking “plantains” ๐Ÿ˜‰ I’m done letting the liberal mass media determine how I talk, I see a long mag curved like an AK47’s, I’m calling it a “banana clip”, and the neckbeards can correct me all they want, they’re just playing into this libs’ hands.

          • BryanS

            Plantain clip FTW.

  • rip rider

    80’s model 3 wheelers and 3d printed guns wtf lol

  • iowaclass

    What’s that other one — a 3D bumpski?

  • BryanS

    It split on a layer. I would think that this would be better suited as a mold master for a good high tensile urethane casting.

    So who wants to try that out with me? ๐Ÿ˜€

  • 3DPrintingGuy

    In FDM style 3D printing it is very important to consider the orientation of the product being printed. He should probably rotate it 90 degrees before printing a new one, if his printing surface allows it. It looks like the crack formed along the seam between two layers.

    • BryanS

      Thats a LONG print. Or, a print with a lot of supports. This file comes made to assemble, and then soak or dip in solvent to solidify it.

  • Maximilian Johannes Benning

    I think this would be a lot better if the p90 style thumbhole grip and buttstock attached to a forged lower receiver in a 2-point system. There’s a place in the grip that you would screw in like a normal AR grip, and the buttstock would attach to the buffer tube some other way. This would be such a fun little SBR.

    • Cymond

      The point of the WarFairy lower was to create a complete AR-15 lower with a 3D printer. The P90-esque grip & design were intended for strength. Using a standard aluminum lower defeats the whole purpose.
      But yeah, I think a P90 style stock & grip would be neat.

  • Ash Hollis

    This design for an AR Lower really needs to come to market. If I had a 3-D printer I would make my own. One of those with an AR 5-7 upper and SBR would be incredible