Grey Jedi Saber Mk1

thingiverse

Decided to build a custom saber over the holidays and things are coming along nicely so far. This basic saber design was created in Fusion 360. The electronics consist of an Adafruit Feather M4 Express with a Prop-Maker wing that attach to two printable cradles, which fit snugly inside the Wrap.stl (main grip) holder. A tight fit past the inside threads, but they do fit perfectly. There are two cradles; one has a large central cutout for an 11mm slide power on/off switch to turn the electronics on and off. The second cradle has two notches that allow power wires to connect to the battery housing. Power is supplied from a 18650 3000mAh 3.7v Li-ion battery in a standard 18650 single battery holder, which fits neatly inside the wrap.stl (grip) inline with the Feather/Wing and closer to the fore grip. Currently, there are no cradle files for the battery, but this may change if battery rattle becomes an issue or I build a crystal chamber. The sound is projected from a 40mm 4ohm 3w speaker that should push fit in the pommel. Disclaimer - on my initial version, this worked fine, but at some point, I changed the thread size/pitch and my second print was way too tight. I have since gone back to what I think was the original thread size and included those files here. Once I have had a chance to reprint the pommel, I will amend those files as necessary. The saber activation switch is a 16mm momentary push switch in the fore grip that fits tightly without needing an inside securing nut. The initial light source is a 7 neo pixel 5v (25mm diameter) spot that fits in the recess on the emitter. This will be replaced with a poly carbonate blade at some point, but I need to buy some 144 LED neo pixel strips first. At that time, I will add another file for this blade emitter so they can be swapped out. All the parts are designed to be a screw fit and I have tolerated the threads (+0.2) for my Ender 3 printer running Cura 4.4.1 on Low Quality (0.28mm) using Prima Value PLA. The connections are tight but not too tight, which was an issue before I added the extra 0.2mm offset on one half of the thread pairs. I have combined all the electronics and plastic together, and everything works great. Currently, I am printing the Covertec belt clip and pommel clip and will hopefully reprint the wrap and pommel (if my PLA lasts). The final .stl file is for a double coupler that should allow both prints to connect together. Yes, I am making two sabers because... why wouldn't you? EDIT: I will be uploading a revised version of the cradles and the wrap .stls (marker _v2). This will include a groove locking mechanism for the cradles as I'm getting frustrated with the boards rotation when turning the main power on and off. Also, a hilt without the wrap for those wanting a plain hilt to add their own texture to. Update 07/02/20: Updated with the Blade version of the emitter, designed for a 25mm outer diameter polycarbonate blade.