Aliens M41A Pulse Rifle - Full Size

“..I'd like to introduce you to a close personal friend of mine.”

This is the M41A 10mm Pulse Rifle from the 1986 Movie, Aliens!

I've wanted a full-sized Pulse rifle for a long time (again surprised there's none on Makerworld already!).
I've tried other models that were really complicated to build, and not having much free time - didn't really get on with them.

This is adapted from Intentional3D's excellent (but tiny!) Pulse Rifle from Thingiverse, blown up to full size (695mm/27" in length).

But, sliced in order to make it easy to print and build, making it accessible for everyone! 

Please be aware this will take quite a bit of post-print work (Filling and Sanding etc) in order to look good.

I'd recommend getting some easy to use Wood Filler to join the inevitable gaps in the body that run down the mag well. And some good High-Build Primer to really finish it off smoothly. 

Joining the two halves of the grab handle is the tricky part. I recommend gluing and clamping the lower part of the body first, and then carefully gluing the handle after in order to get a good, straight join. (You'll notice that the handle on mine has a noticeable join - something I'm working on improving and will update once I've come up with a solution!)

I look forward to seeing your prints, and as always, if you encounter any problems, please let me know and we'll see if we can fix them together.

UPDATE: 23rd October 2025 - A lovely person called Dan has tested and successfully printed the A1 Mini Profile, so you can now printed a full sized pulse rifle on your tiny printer bed!

You can find it at the top of the page. Many thanks to DanJ - I recommend you check out his profile https://makerworld.com/en/@jayberg

-Lewis

Design by L3wisD on MakerWorld (license: BY-SA).