3D Printed Lightsaber

How to make your own 3D printed lightsaber:

Diy Kit (Now Availible!)

3D Printer

Lightsaber Files

3ft by 1in Acrylic Tubing

LED Flash Light (Red, Blue, or Green)

1s LiPo Battery

Voltage Step Down

Soldering Iron

Switch

Toggle Button Switch

Charging Port

Parchment Paper

Filler Primer

Bondo Glazing and Spot Putty

Hilt design can be accomplished with 3D designing software (of your choice). For beginners, Microsoft 3D Builder is great (and easy to use) software. I used Fusion 360, which offers advanced features. While designing, keep in mind that 3D printers are not perfect; make any openings 0.5 - 1mm larger than they need to be, so the parts fit properly during the assembly phase.

To design it:

Start with a hollow cylinder and split it in the middle. The cylinder needs the split in the hilt so that electronics can be added later on. I suggest you add registration keys to the design, so when the lightsaber parts are glued together, they will be properly lined up. Alternatively, threads could be designed into the cylinder, so parts screw together and do not need to lined up and glued.

Next, customize your cylinder design. Add all of the details that you want. For example, your lightsaber could incorporate Star Wars details or you could create custom details.

You will need a flashlight in order to illuminate the blade and that flashlight needs to be able to slide into the hilt. The flashlight that I linked to this post has an outer diameter of 25.4mm, which is the same diameter as the blade. In order for the flashlight to fit inside the hilt, I designed the inner diameter of the lightsaber hilt to be 25.9mm.

The flashlight operates by LiPo batteries. Therefore, you must ensure there is room for batteries to fit inside the hilt. The linked batteries have a width of 29mm. I ensured that the hilt was wide enough to hold the batteries. Be sure you factor this into your measurements/design.

In order to activate the lightsaber blade, you need an activation switch. When designing the hilt, a simple hole should be added to the design to house the button switch. (The linked buttons have a diameter of 12mm)

The bottom of the model requires a cap, which holds the charging port and power switch in place. This cap can be threaded or glued in place.

Notes about the provided files: The files provided include 3 STL files and one Fusion 360 file. These files may be edited for personal use only. These files do not include a completed cap design, as it is missing a hole for the charging board. The charger that was used in this build was a simple micro USB connector. I do not recommend that you use a USB port as a charger (link for more info). As soon as I get one, I will update the design files.

**The provided hilt files are for personal use only. The BladeTip file can be used commercially**

Now that you have your hilt designed, print it yourself or have someone print it for you. DIY kits will soon be available in my Etsy store!

Once the hilt is printed, test fit the electronics and blade before moving on.

You will likely see print lines on the exterior of the hilt. To reduce these lines, sand all parts.
I recommend starting with a low grit (60-120) sandpaper. Next, move to medium grit sandpaper (180-220) and then work up to a higher grit (320-400).

Once sanded, spray 1 coat of filler primer on the hilt. Sand the hilt with medium-grit sandpaper (220). Repeat this process 3-4 times.

If noticeable defects (lines) appear on the hilt, Stage 3 Bondo can be used to smooth them over. Apply Bondo to desired areas. Let dry completely (3-4 hours). Sand with medium-grit sandpaper. Apply 1 coat of filler primer. Sand area with medium to high grit sandpaper.

Now that all print lines have been corrected, be sure to test the fit the blade one more time before painting. If the fit is loose, some tape can be added around the bottom of the tube. If the fit is too tight, sand the opening wider.

Before painting your hilt, I suggest you test different paint color combinations on the 3D model. This can be done in Microsoft 3D Builder, Fusion 360, or another 3D software. Once you have determined the desired color, it is time to paint! Paint it however you like; colors could be based on an existing design or could be your own custom design.

While painting and sanding, make sure to be in a well-ventilated area and wear appropriate respiratory protection.

Now that the hilt is finished, the electronics need to be added.

Take your flashlight and remove the LED. The AA battery chamber will not be needed again. If you need help, refer to the attached video (Recommended clip: 1:24-2:15). In the video, at 1:36, they use a pick to unscrew the top of the flashlight but pliers can also be used to grab the silver part to unscrew it.

Once you have the LED housing removed from the flashlight, the circuit board needs to be removed. This can be done with a small screwdriver used to pry it out. This board will not be needed again.

Next, put the led module back into the focusing lens housing. Then use CA glue to lock the lens in the focused position. This is an optional step, but it is useful to keep the flashlight from coming out of focus.

Next, reference the wiring diagram (see image) to see how to wire the components together.

Before gluing your Lightsaber together, test to make sure that the electronics work as intended.

Now you can glue the lightsaber hilt!

Now that you have a fully assembled hilt, it is time to add the blade.

Cut the 1-inch acrylic tubing to 3 feet.

Next, roll parchment paper and insert it into the acrylic tube. This creates the effect of light diffusion.

Once the parchment paper is in place, the blade can (but does not have to) be permanently glued into the hilt. Note that I chose not to glue the blade into the hilt so the blade can be swapped to other hilts.

Last, a blade tip can also be added to the top of the acrylic tube, to cover the end of it. You can use a clear filament to 3D print this part and glue it in place.

Congrats! Your own custom printed lightsaber is finished! Post a picture and share it!

I hope you had a good time with this build!