Customizable crossguard lightsaber, from The Force Awakens

by LeFabShop, published

Customizable crossguard lightsaber, from The Force Awakens by LeFabShop Dec 1, 2014


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On Friday, November 20th, we were part of the 30 million people to keep their breath while watching the trailer for the next Star Wars movie.
As designers, we were surprised to discover a new configuration of the lightsaber revealed in the now epic (and polemic) scene showing an unknown Sith Lord walking in a snowy forest.

As Makers, we couldn’t help but try to find out by ourselves if this “crossguard” design was a good configuration or not... So we decided to build one, with our army of 3D printers.

Of course, the "darkness" of the movie sequence and the lack of details on the weapon itself left a lot of place for imagination and interpretation.

A dozen of 3D printable lightsabers being already available for download on internet, we decided to make one that would be completely customizable. The modular system we invented makes hundreds of configurations possible. From Yoda’s lightsaber to Darth Maul’s.

Here's complete video of the crossguard saber's assembly, and in action : https://www.youtube.com/watch?v=L-RrAKZHkwc


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What filament was used to print the red laser?

How can i print the lasers in Cura? Every time the model loads i get a solid top and bottom!!!

Will this laser print on a Z axis of 180mm?? Seems very close..

Making the Kylo Ren saber. I got most of it done a while ago and decided it shouldnt just sit there and take up space so im finishing it now. Only the big blade and one more side blade left :D

How did you get blades to print? I am using Cura 3.0.3 and it keeps making the top and bottom solid.

The entire top of the file is supposed to be solid, but only the central circle is supposed to be solid on the bottom. The blade prints upside down from what it will look like eventually. Since I don't use the software you do, my best suggestion of what to do is to make sure rafts and brims are turned off.

Comments deleted.

I wish there was a curved hilt in the files. = /

Can we please have an editable file. I need the computer dimensions of the blade

how should the lasers be printed? with or without support?

I hate to be an obnoxious uber-nerd, but lightsabers use plasma blades, not lasers. Also, I have no idea

Yea. I'm that kind of person too XD I only called them lasers cuz thats the filename for em

the single button segment is the same as the double...please fix :)


There is small switch file missing. Can you update? And please tell me what settings you used on MB printing the lasers?

Well, The Force Awakens is out, and I have to say, I'm kinda disappointed that Rey defeated Kylo Ren on her first time picking up a lightsaber...

Erm... The instructables link is a 404.

Great design and stuff!!!

Would this fit on a Printrbot Simple (150mm3)?

I really wish you guys would revisit this design. It's a really cool idea, but a lot of your parts are wrong or missing and you could really expand on the handle attachments. Or at least realise the design files.

I agree with that

This design is awesome!!
I have been trying to print the for the past week.
All the parts printed flawlessly, except for the laser. I have changed almost every setting and I still am running into stringing problems. I cant seem to get the laser out no mater what I do so I have decided to ask for help.
I am open to any suggestions

i saw it in youtube :) fin

Ok no idea why people aren't commenting. This design is awesome!

Laser problems: I figured out (in Cura) why I was getting stringing resulting in the lasers sticking together. I changed all of my refraction settings, decreased the print temperature, and increased the move speed. Nothing. Then I changed the refraction settings.

What finally worked was I changed the "refraction: minimum travel (mm)" to lower than 1.3. Looking at the layers, if the first layers has refraction lines (the blue lines that go up "z-axis") between the rings, then you're good. If it's flat, then lower the #. Make sure you don't go too low or the middle refracts too, which isn't bad since it's only 3 layers.

What fill did you use for all of the parts? (body... and the laser)

This design is AMAZING!

Also, do you have a medium size laser? My print bed can't handle sticking for 10 hours and I think the tiny laser is only for the cross hilts.

I think the cross hilt would be extremely dangerous to the wielder... I have fought using such a crossguard and it can be very useful for trapping another blade however, with the nature of the lightsaber, any close combat would likely get you injured by your own cross blades, especially if they are more than a couple inches from the hilt. Cool looking but highly impractical to wield. The 45° angled idea would be only marginally better unless it were made of a lightsaber resistant material.

How would this do with swordfighting?

So I'm trying to print this out on a Flashforge but I'm having issues with the laser portion. I use ReplicatorG for my .stl files but cannot convert them to a .x3g file. Does anyone have a working .x3g file or some advise how to make this work. Please I really want to make one ( or more ) or these.

In the third image what color is that closing cap?

That's just awesome. Great job.

Only issues I am having is trying to make the different light sabers like yoda or Vader. Knowing what parts are what colors for the different hilt parts. so many parts gets a little crazy.

anyone ran into issues when printing the laser? the shell seem to stick together...


any advice?

I'm guessing that you've got some support material being added. Try turning that off in your slicer?

I printed it without support material. I needed some narrow tip tweezers to work them loose once finished (a couple of mins of wiggling total)

i have no supports on...im guessing its oozing. im playing around w/ the retraction setting to see if that will do the trick

Oh, yeah you really want to solve any oozing issues before printing the laser or you'll never get it to come out nor fully extend.

I used 0.6mm retraction on my printer (1.75mm E3D v6 extruder)

Any chance you could upload the "single_control_button.stl" again, currently it's the same as double_control_button.stl

Thanks and awesome design, will post photos of my printed one tomorrow.

this is still true.

How do you get the blade to extend? The blade segments are stuck to the bottom cap, and I can't free them

Your first layer might be too tight. Try using raft. Le FabShop logo should be on top.

I tried with a raft, but my max print height is 150mm and the laser is 149mm I believe. No raft room :(

OK I was printing the lefab logo on the bottom. I'll try another one and seee how it turns out. Thanks!

will it print well scaled?

The tolerences are very tight. I doubt it will work.

Awesome idea and design!

Fantastic design! Having fun deciding how I want mine to be.

One thing I noticed in the files, the single control button file seems to actually be the double button one.

I was wondering how long it would be till I saw one...then I saw this! WOW O_o Nicely done.

Well that was fast.

thats what I said!!!!!!!!!!!

The picture on the stairs was worth the price of admission. Nicely done. :-)