A USB rechargeable lightsaber inspired by The Force Awakens' exotic new lightsaber. This was a collaborative project completed by Ethan Ouimet and Eric Thomas. The model was designed and painted by Ethan and file was adapted and printed by Eric. The idea of making the lightsaber was pitched and started on a little more than a week away from Star Wars day. We were able to complete it, get it to light-up, recharge off USB, and paint it. The .stl files are included as well as the Fusion files that can run on Autodesk's Fusion 360. It's free software to students/ enthusiasts.
Used a Dimension 1200es printer for the final pieces, but the sample tests printed fine on a Makerbot Replicator. If you have a smaller printer, then you can slice the file using Fusion/ meshmixer into smaller chunks to print and assemble.
The FrontPlate has holes for a 3mmx8mm screw to mount it onto the Blade Emitter.
The BladeEmitte is hollow and houses the battery and lights. There are 3x red LEDs with resistors soldered in parallel to a 3.8v LiPo battery.
The GripSection houses a regulator running to a striped Female USB cord and leads that connect to the battery when the two printed parts are connected.
Note that the GripSection and the BladeEmitter are friction fit pieces.I decided in the short time that I had to not add a grove or slot. The pieces should fit snugly; if not, lightly sand until they do.
The blades use polycarbonate tubes. The Main blades uses a 0.5in OD tube, while the side blades use 0.4in OD tube. Blades sizes are not exact. For the sake of short time, the tubes were hot glued into the locations. If you glue into/ around the inside threads, then the tube will have a tighter lock onto the inside surface. I was able to source polycarbonate tube from a local plastic company.
To achieve a good light piping you can place cellophane inside the polycarbonate tubes. Wrap the cellophane around something like a dowel rod, then insert the rod and wrapped cellophane into the tube. From there just gently slide the rod out leaving the cellophane wrapped inside. You can pick-up cellophane at a dollar store.