Introduction: 3D Printed Lightsaber

Necessary Assets:

123D Design Software

Makerbot Software

3D printer

3D printing plastic of your choice

Sand Paper

Step 1: Design the Hilt of Your Lightsaber

  1. Draw a circle of your desired girth that you would like your hilt to be using the circle tool on the grid of your design software
  2. Extrude the circle outward to your desired length. Use the fillet tool to round off one edge of the hilt so it looks like the bottom of a lightsaber.
  3. Draw an additional circle (skinnier than the girth of the hilt) on the flat end of the hilt and extrude it all the way through so the hilt is hollow until capped off by the round fillet edge.
  4. Create two torus in the design software and put them on both ends of the hilt so it starts to take the form of a real hilt. Torus can be found under primitives.
  5. Draw a rectangle on the middle of your hilt and extrude it all the way through to the hollow inside so there is a gap for a an adjustment knob. Only one side should be extruded, not both. (can insert a rectangle sketch from primitives.
  6. Add any additional hilt ideas you may have to your hilt.

Step 2: Design the Saber Portion of Your Lightsaber

  1. Draw a circle of your desired girth that is slightly skinnier than your hilt. You will use this as your saber so it must fit inside the other circle.
  2. Extrude this circle to your desired length. Preferably longer than the hilt you made as it needs to be proportional. But not too long so that the 3d printer cannot print it.
  3. Fillet the end of this saber just like you did to your hilt, so it has a rounded edge.
  4. Draw a circle on the side of this saber that is big enough to hold the adjustment knob you will add later. You can find the circle to attach in primitives.
  5. Extrude the circle through the blade to make you hole.

Step 3: Design the Adjustment Knob.

  1. You begin by drawing a half circle comparable to the thickness of your thumb size.
  2. After you get the ideal knob for your thumb you need a sufficient cylinder to pass through both the hilt and the saber to be able to adjust your saber.
  3. You must make sure that your cylinder is a solid object and not hollow or else it will snap. Also, you must make sure that your cylinder is thin enough to pass through each hole.

Step 4: Print and Assemble

Use Makerbot to print out the finished design. Make sure the design prints out solidly, and not hollow. Put all pieces together after sanding to make sure everything fits properly.