Build Your Own Lightsaber! - V2.0

prusaprinters

New and improved customizable lightsaber! Pick and choose any combination of parts to screw together and create your very own lightsaber hilt! There are over 10,000 combinations! Some of these parts are inspired by the extended Star Wars universe, while some I have built from scratch.  New Changes from Version 1:Now instead of each part having a male and female connector, I have made one long core thread that all pieces screw onto. This helps with the strength of the threads as it will be printed length wise on the build placeThis gives more freedom to place pieces in any orientation, as well as add spacers between larger parts for more accents and individualityFixed stringing issue in interior threadsFrom a design stand point this system helps streamline building the hilts in CAD softwareSaves on material, I find 10% infill on body pieces is sufficient, you only need to print the core once (or more if you want multiple hilts), and all the pieces are now more hollow than they were beforeUnfortunately if you have printed any parts from my previous hilt designs, they will no longer be compatible with the exception of some buttons and switches.  Printing instructions:I print with a variety of brands and printer models so I've kept the tolerances a little loose for easy compatibility.Core: Print diagonally on build plate0.2 mm layer height60% infill, this is the major structural support, 60% is recommended.Note that for the core this design has more strength lengthwise but cannot withstand incredible torque around its axis. These parts should not apply much torque when screwed on snuggly. If you experience any resistance while screwing on a body parts consider scaling the axis cross section down while keeping the length the same. On my first print of this design I completely sheered away the core and it got stuck in the body. The looser tolerances solved this, but be aware.    All other pieces:0.2 mm layer height10-20% infillNo brims or supports unless otherwise stated. Some pieces you may have to orient in your slicer so the flat side faces down. Though the core is now much stronger, this means that the interior threads are likely to give way first. Though you can still tighten the pieces more than before, avoid making it too tight. Building Tips:Build inside out. Once you've decided the parts you want, screw the grip or centre pieces on first. If you screw on the pommel or emitter first there will be lots of turning in your future.The emitters and pommels have much more thread space than they need to screw on securely. You should only have to reserve about 1cm on either end of the core to secure them. I've given them more space to give a little extra room for diversity, if you want less parts or a shorter hilt you shouldn't have to print spacers if you don't want them.I've included the height of all the body pieces in the notes so you can choose the appropriate size coreI have curated the selection of my favourite buttons on this file, though my previous posts have buttons that will be compatible if you want more optionsKeep it simple. You don't need a lot to make a beautiful hilt. A pommel, an emitter, a grip, an activator, and maybe a few short pieces and spacers to bridge the gaps. The Kestis saber is one of my favourite build with this system, and its only 4 pieces.Get creative. The point of this project is to not be restricted to one set of designs or parts, mix and match and make your own. I've included the thread specs below if you want to make your own part, or make compatible designs others have made  Specs to make your own parts:I made this in onshape, browser based CAD. The files are completely public and can be found here. Threads: Pitch: 4.4mm Height: 2.42mm (attached an equilateral triangle with side length 2.8mm to helix, filleted with a radius of 0.8mm on the protruding point)Core: 14mm diameter, threads added to cylinderBody Pieces: minimum 23mm wide, extrude a 15.8mm circle through piece (16mm for loose tolerance, 15.4 for tight) threads removed from partButtons: Pitch: 1.5mmHeight: 1.21mm (1.4mm equilateral triangle)On the part: 6mm interior diameter 4.5 mm depth with threads removedOn the button: 5.2 diameter screw 4mm in length with threads added Let me know what you think, if there are any other Lightsaber hilts or parts you want to see! If you make a part post it to share! Update 5/23/24 - Updated Cordova pieces, added Jocosta saber parts, added extra large and extra small core pieces