Last spring my grandkids were playing with bubble wands in the back yard. When they were done we had several of the empty wands. Since we do not have recycling I was looking for a way to avoid throwing them in the trash.
I saw several lightsabers here so I thought I would attempt to make ones that could use the bubble wand tubes as the blade.
This is the result of an attempt to duplicate the "Luke Skywalker" lightsaber from episode IV.
All the parts have threads so they screw together so they do not require any glue to build them.
You can use http://www.thingiverse.com/thing:1726373 to help making the LED column
You will need a printer with at least a 260 mm Z to print the light column insert.
I printed everything using PLA.
For the Deflector Ring and Radiator you are going to have to use a heavy infill to handle the stress on the connecting threads.
Post Build notes.
You will need 30 6mm LEDs per saber.
The LEDs are wired in parallel. You will have to careful to maintain the polarity of the entire column, I had a bench supply and set the constant current mode with current limit @ 400ma so I could test the column as I added LEDs
You will need a current source of 300 - 400 ma.
The voltage will vary based on the color of the LEDs.
I printed the diffuser with clear PLA, with 30 LEDs the color of the Bubble wand tube will be overridden by the color of the LEDs.
The included electronics sled was designed to hold a 4-AAA battery holder and a circuit board with the power supply for the LEDs. The board I build had a connector to the battery holder, a connector to the light column and a connector to a switch mounted inside the trigger housing. I used a 555 set to be a PWM which is tuned to provide the current and voltage that the light column requires.
The ON/OFF control is provided by a momentary switch mounted through the hole in the Trigger housing.