EDIT (10/12/15): So I've just come across this other design on tested.com and it looks like this guy has done a way more professional job than me so I'd recommend checking that out first:
https://www.youmagine.com/designs/star-wars-lightsaber-complex-version (complex print)
https://www.youmagine.com/designs/star-wars-lightsaber-normal-version (simpler print)
This started out as a model I did years ago to recreate a prop I saw being sold online (an accurate one). I wondered what it would take to make it printable on an FDM printer so I set about splitting up the model (for the sake of overhangs) and attaching threads. I've come up with what you see here.
Note that I did do a test print but I had warping, the model did the job nicely but the print isn't pretty (not the models fault, but the cold weathers fault...).
If you have any questions then feel free to message me.
Some notes (UPDATED):
-The curved pieces the blade activation button panel is supposed to slot into did not print in my test print but I think I have now fixed this. If you find this does not print then please do tell me
-I used a flashforge creator to do the test print
-This model is 28cm tall when constructed, 1:1 scale
-The spacing between the male and female threads is 0.3mm
-ABS is recommended for the sake of the threads, as is more than 1 shell
-That circular unthreaded piece sits between two pieces which screw into each other
-For reference the build size box you see in the two complete assembly model pictures is of a flashforge creators maximum build size
-The smaller parts may need to be glued together, they are too small (for me at least) to do proper detail with as they are
Plans for a future iteration of this:
-Blade fittings - someone requested a model where you could fit on blades you can buy from places, I plan to look into this and add it in
-Smaller parts that actually clip into each other and onto the blade (they STILL don't which is proving tricky...)
-Better topology around the square holes (as the loops I had to put in added sharpness where I didn't want it). This is barely noticeable and very low priority though
-Dissassembly options for electronic inserts (light lights!)
- Print it in ABS, 3 shells preferably and some infill so things don't snap (the more the better but it obviously adds a lot of time). You could do it hollow if you print with interior supports (with replicatorG this is just the 'full supports' option)
- Screw it all into itself using a picture as a guide but be careful as you do this so it does not snap
Note: Do not print this in PLA without a fair bit of infill (although you 'may' be okay with slow print speeds), the threads do not like it...