I have modelled this to be as accurate as possible, using the Prop Shop Kylo Ren Lightsaber as my main reference.
I have put together a guide on finishing the 3D printed pieces, which you can view here: http://www.magnaprops.co.uk/guide-how-to-make-an-awesome-3d-printed-kylo-ren-lightsaber
If you print the lightsaber, I'd love to see your results! Please tweet them to me https://twitter.com/MagnaProps
For best results, print at 0.1mm layer height minimum.
For best results, print the following pieces at very slow speeds (I printed at 15mm/s)
This may vary depending on your printer, and how well it handles small details.
Most of the parts require some supports. Bottom-Greebles.stl can be printed without support.
Print at 10% infill. Smaller pieces you can print at 100%.
Bottom-Greebles-EXTRA-DETAIL.stl has some extra details included which won't print well on most FDM printers. I've included this for anyone using a resin printer.
I have included an 8mm hole through the middle of the pieces, so that you can insert some 8mm studding for extra weight and sturdiness.
Most of the pieces should snap together. Some connections may be a little tight, but they definitely all fit! (I've made 2 of these lightsaber now, some gentle encouragement may be required)
I have also included a display stand for your finished lightsaber. Make sure the slightly longer of the two arms goes into the left slot.
I have also included a printable lightsaber wire clip, in case people don't want to make their own from metal. This is completely experimental, and I haven't tried printing this yet. But cura seems to think it will print just fine. So give it a try, and let me know how it goes.
If you encounter any problems with the files, please let me know. I have printed most of the pieces multiple times now on a Wanhao i3 Plus without any issues.