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Does anyone have any files for 3D printing a thunder Hammer? I'd like my buddy to print me some custom thunder hammers for my slam captain conversions for an APOC game coming up. Two handed would be cool but single handed would be ok too.

Search for "hammer" on Thingiverse.com is my advice.
Also, note that bits of that small size will require a high resolution printer, usually with liquid resin instead of plastic spools.

Yeah, just search for 'Hammer' and scale it to suit.

Thinking about the handle, has anyone ever printed a part with anything inserted part-way through?
I'm thinking about a groove for a brass rod through the handle, added as it prints.
Is it just better to try leaving a bit of a groove as a pilot hole to drill into afterwards?

I did exactly this and found 1. It's nice I was hoping for more options though. Maybe something with iconography already in it like blood angels and space wolves.