Star Wars Rebels - Kanan's Lightsaber

thingiverse

I made a custom piece as a commissioned work for a cosplay costume back in December. After discussing it with my client, we've decided to release it on Thingiverse. Check out my Blog for more details on the design and printing of this piece: https://fabricatingrealityblog.wordpress.com/ Print Settings: Printer: Flashforge Creator Pro Rafts: No Supports: No Resolution: 0.2 mm Infill: 20% Notes: I printed it in PLA filament, making a total of 19 pieces. To get the best results, print at speeds between 40 and 60 mm/s. For all but the smallest parts, I used 20% infill; smaller ones were printed at 100%. It took me 19.25 hours to print all the parts, using about 85m of filament (less than a quarter kilo). How I Designed This I created this lightsaber replica based on screen captures from the Star Wars Rebels animated series on Disney XD. Working from stylized proportions and scale, I used a lot of eyeballing to get the correct look and feel. While it may be slightly too long and fat, I'm pleased with my results. Using simple polygonal modeling in 3ds Max, I cut the pieces using ProBooleans, allowing for a general tolerance between pieces of about 0.2 to 0.4 mm. Each interface between parts is unique, so assembly is possible only one way. Assembly Instructions Files labeled "00" are inlays and detail pieces. Print each STL file except 00c-Kanan-MagneticChoke_x2.stl, which requires two copies, and 00e-Kanan-GribRib_x7.stl, needing seven copies. Assemble the pommel, haft bottom, haft set pin, haft top, magnetic stabilizer, neck bell, blade emitter by gluing them together. After gluing in the grip ribs and face, install the rest where they fit.