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This is a fully open source 3D Printable Ninja Sword Lamp. It is both easy to build (providing you have access to a 3D printer) and very affordable. My total cost to build was less then $32 and I have included links to where I purchased the electronics. These parts can be found from many other vendors. All links provided are not to be considered endorsements. They are simply where I happen to make my purchases. The build took about an hour including the hand filing of 3D prints and was very simple. That time frame does not include the time needed to print the pieces. This lamp is super bright, easy to control and it looks awesome!


Specs:

Height: 31"
Widtgh: 4.5"
Voltage: 12V
Amperage: 1A
Colors: 7
Control: IR Remote
LED wavelengths: 630nm/530nm/475nm

Step 1: Hand File and Pre-fit All 3D Printed Parts

For cleaning up prints I prefer a set of small hand files of various shape and size. This method is both clean and precise however it is tedious. Feel free to use a dremel or whatever method you prefer. The areas of importance are the inner circles of all the various handle components. Take care to file down any zippers and hand fit prior to heating up the hot glue gun. 

Bill Of Materials:

1. 1m RGB LED Strip Light Purchased Here: Adafruit For $16.99
2. LED Controller Purchased Here: Amazon For $6.99
3. 12V DC 1000mA Regulated Power Supply Purchased Here: Adafruit For $8.95
4. Hot Glue Gun
5. Electrical Tape
6. Hot Glue Gun
7. 5mm tall rubber bumpers
8. All 3D Printed Parts. Files Are Available For Free Download Here: http://www.thingiverse.com/thing:67433

Step 2: Assemble the Base

1. Add the bumpers to the bottom of the 3D printed lamp base (leave room for electrical tape. It is used to cover the white control box)
2. Insert the LED wire connection through the whole in the base (Do not insert the IR receiver wire)
3. Push the control box into the base making sure not to pinch the wires too tightly and leave some space at the top
4. Take the IR Receiver wire and tuck it into the remaining empty space of the base again making sure not to pinch the wires)
5. Position the end of the IR Receiver towards the front of the lamp base (Make sure there is a clean line of sight for the remote)
6. Use electrical tape to cover the control box and IR receiver up to the black plastic (Do not cover the black plastic receiver!)
7. Lastly flip the lamp base over and gently coil the wire down through the hole in the base. Do this until just the connector pops out of the hole.

Step 3: Connecting the LED Strip to the Control Box

1. First cut the 1m LED strip to the size. Then insert the wire ends of the LED Strip into the connector. The Black / 12V wire goes into the slot with the arrow. After that the order is BLUE RED GREEN. Take note that the order of the actual wires is GREEN RED BLUE so you will need to twist & swap the Green for Blue. This step assumes the wire ends of your LED strips are already tined as the ones I used

2. Once All wires are well connected attach the 12v power supply and test that the lights function properly. Make sure red is red, blue is blue and so on. 

3. Use hot glue to prevent the wires from popping out during construction. I did this with two strips of hot glue. A thin line on each side of the wires should do well. Do your best not to use too much hot glue and melt the wires

4. After the glue dries fold the loose wire over itself a few times until the first LED on the strip is about 1" from the base. 

5. Wrap the connection loosely in electrical tape. As always don't pinch the wires too tightly

6. Slide the base ornament over the LED strip and use the hot glue to attach it to the base. Make sure it is well glued down because the entire body of the sword attaches here. 

Step 4: Assemble and Attach the Handle

1. Tightly hand press the translucent extenders into opposite ends of the handle

2. Next repeat with the opaque extenders and make sure to insert the hand guard at the top before pressing the extender (You could also print the extenders or hand guards in various other colors to add some customization)

3. Press the handle base in and then press the entire assembly against the ground. Make sure all pieces sit flush or your lamp will be tilted. 

4. Slide the handle assembly over the LED strip and set it up centered on the base

5. Once you have it positioned the way you want  apply the plastic glue generously to the base and use hot glue to tack it in place while it dries.

6. Pull the LED strip tightly and flush with the top of the handle

7. Tack the LED strip to the handle with the hot glue. Make sure you do this on the 2nd from top extender. If you tack it into the top extender the blade will not slide in. 


Step 5: Attach the Diffusers and Blade Sections

1. Place a thin strip of hot glue down the center of the diffuser. You are glueing the top of the arch and not the two feet. It seems counter intuitive but it offers the best diffusion of the individual LED's. 

2. Quickly press the hot glue side to the LED strip. Make sure to start just below the handle. 

3. Next slide the blade about 1/2" into the handle and hot glue all the way around the bottom

4. Again pull the LED tight and straight to the tip of the blade and tack it in with the hot glue

6. Repeat the process for each section of the blade. Use a minimal amount of hot glue to connect the blade sections. If you get all the sections together and some are offset do not worry. Simply use a soldering iron or the tip of your hot glue gun to loosen the bond and nudge the piece into place. Take care not to melt your plastic pieces. The last diffuser will not fit all the way up the coned tip of the last blade section. Just glue it down overlapping the last diffuser so that it fits.


Step 6: Tack It Down and Enjoy!

1. Lastly tack down all press fit parts with hot glue 

2. Power it up and enjoy your handy work!
This actually gave me a really great idea for part of a Rex Power Colt costume. Thanks for posting! :)
Nice project. This is a cool use of 3D printing.

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