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Lightsaber with internal components mega project!

by sirmakesalot, published

Lightsaber with internal components mega project! by sirmakesalot Nov 20, 2012

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Description

Be come the Jedi you were destined to be! Manufacture your lightsaber and take your place in the battle between the Jedi and Sith! This is a complete user assembled model of one of the greatest allies a Jedi has! "Your lightsaber is your life"

Recent Comments

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I printed the whole thing out and must say I love the design!! There are a couple of things that I think need some fixing. I recreated the whole thing using the parts printed from your design. Pretty tight tolerance.. With the revisions I have made, the cap "should" slide onto the body. I have also put a ring around the three tabs that are prone to break off and the internal parts will be tight in the case. I noticed that they were a little short from top to bottom.. I created a crystal as my slicer didn't like the STL of the one on here.. I will post in the next week or so after I print it all out.. I will be sure to link yours. Awesome job on designing this!!! I tried to keep it as close to the original design as I could.. (All done in Designspark Mechanical and printed on Zortrax M200) I will also post pics of the first print when I get a chance.. Keep up the great work!!!! Not sure I could have pulled this design out of my head.. What did you use to model this?
file for the original crystal?
the one shown is different from the stl and to be honest i think it looks cooler
This is an awesome model! I just can't figure out where the "buttons" go....

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Instructions

Use the ZIP file for all at once download. I changed some files for greater tolerances for all interconnected parts. Pleas let me know if there is a problem. I will change the files if I find any here. Print, paint and assemble all components. Zip file has all components or download individual parts. The Chrystal goes in the chamber and then capped. Glue the two lower body sections together (body one and three,) ribs on body one and cap and buttons on top section (body2). insert bottom, battery, assembled chrystal chamber, amp chamber and beam chamber in lower body sections. Gently wiggle the body top on. You may have to sand down the tabs a little to encourage them to go over the rib without cracking. Body three and two should snap on and hold it all together so you can open it later to service it or put it on display. Order of components assembly to come in the form of video soon along with pictures. The parts only go together one way and isn't too hard to figure out. Be warned the crystal may need to print with support. I had trouble rendering a good looking crystal. I may make my own by hand or harvest one! Print some components in different colours for variations. I can't wait to see other copies! I am releasing a kit of parts next that you can mix and match for more variations so stay tuned!

I printed the whole thing out and must say I love the design!! There are a couple of things that I think need some fixing. I recreated the whole thing using the parts printed from your design. Pretty tight tolerance.. With the revisions I have made, the cap "should" slide onto the body. I have also put a ring around the three tabs that are prone to break off and the internal parts will be tight in the case. I noticed that they were a little short from top to bottom.. I created a crystal as my slicer didn't like the STL of the one on here.. I will post in the next week or so after I print it all out.. I will be sure to link yours. Awesome job on designing this!!! I tried to keep it as close to the original design as I could.. (All done in Designspark Mechanical and printed on Zortrax M200) I will also post pics of the first print when I get a chance.. Keep up the great work!!!! Not sure I could have pulled this design out of my head.. What did you use to model this?
file for the original crystal?
the one shown is different from the stl and to be honest i think it looks cooler
This is an awesome model! I just can't figure out where the "buttons" go....
So i'm new at this and was wondering if I should change the speed of the extruder and how fast it travels to get the best quality.
Hst - in reply to Kevdw
it depends on the printer something like an Ultimaker can deliver the same print quality at almost any speed, but most printers for the best quality print you should print at around 40mm/s. But it still really depends on the printer. To answer your question slow you print at higher quality your print will be.
Che figata!! (sorry in italian sounds better!) Really a great job!!
Awesome - I look forward to the print!
I *think* body1 and body3 are meant to be glued together as well, but body3 and body2 should snap-fit. However I managed to snap off one of the three prongs on body2 several times now. Any advice on how to get these to work nicely? Otherwise you can't take the thing apart to show the internals...
Found the comments on Jerry_XYZ's make of this, with the solution of filing body2 in three places to make the parts slide into place and rotate to lock. That's a good idea, I'll try this and report.
I am working on something like this as a new post...stay tuned!
I printed this off, and I noticed that the Cap and the Body2 are suppose to slide on to each other, but the slot on the cap is not big enough. Is this part of the design? or do I need to sand down Body2 so it will fit?
The cap has a support ring on the inside that needs to come out. Use needle nose pliers and clean up the edge and it will fit the body section.
I pulled the small support ring out, and I noticed that there is about a .5 to 1mm gap around the body2 to cap. so the cap is loose and does not stay on. or this does not matter just glue it together?
Just glue it up! It was meant to be glued on. I left a wide tolerance in the parts as some peoples profiles could be better or worse. I found with the Replicator accelerated defaults I was getting very slightly oversized parts.
same with my Replicator. I print at .2mm layers at normally 50-60mm a second. If I set something to 2mm I will get 2.17mm after it prints. Thanks again for you help. This item is awesome!
Glad you like it! I thought it would be a hit here on the 'verse!! Be sure to post a pic of your copy!!
can you make a youtube video about this print?
This is pretty cool. Love the detail. My 0.5mm dia nozzle has proven a bit challenging on some of the thinner wall items, especially "body1.stl" and "amp chamber.stl". Better slicing success will be likely with a 0.35 mm nozzle.
I made a crystal that works without support, if you want the .stl I will email it to you for your work in progress - PM me
I would love the crystal .stl
There is a crystal file already up there. If one is to be a true Jedi one must collect their own. For me it meant I hand made mine. ;)
If I can find my file Ill shoot it over.
I'd like a copy of that support-less crystal!
Has anyone sliced and printed Body1 with a 0.5 mm nozzle? My printer's struggling with that one (slic3r 0.9.7, and 0.7.2b both). The thin walls seem to be an issue. Suggestions welcome.
You might try running it through Netfab cloud service. Or try scaling it up a very small amount. Perhaps that would work. I am unfamiliar with slic3r and use a .4 nozzle.
I definitely need one of these :-)
How long until Lucas sues?
not Lucas...Disney...even worse ;)
Awesome! Your pieces look really nice! I'm guessing you need supports on some of the other pieces as well (like the amp chamber)?
All components will print without support with exception of the current crystal model.
The crystal looks like it could be printed in two halves and joined afterwards. If the angles were carefully crafted it might even print as a shell only.

I suspect good Jedi warriors are adept at making a crystal that correctly focuses their own energy. Because they will be attuned to the force and their tools ;-)
I will be revisiting the crystal soon. I know it isn't the best solution and I opted to hand fabricate one for myself, it is the Jedi way.
i am now really disappointed in myself that i haven't printed something like this before now
Redeem yourself by printing it! :)
its going as we speak
Wow, This is great!
Do I have a choice but to make this one day?
Nice!
Would it be possible to get a zip/rar with all the parts in one file?
The zip file is up!!
Thanks a bunch!
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