You can find a 3D printed lightsaber in just about every size and shape to mimic every instance of the weapon you can think of, but the version we have today is a bit different as it focuses on what’s inside every one of them: a kyber crystal.
Maker Philipp Kruppe has recreated the internal of a lightsaber complete with this important element that glows thanks to some transparent filament and LEDs embedded in the print.
Krupped tells us that this project started with modelling the print in Solid Edge, a CAD programme from Siemens that we don’t see used too often by those featured in our 3D Print of the Day series.
This process took around two hours to complete, but that was only for the internals as this project is divided into two parts: an inner part where the crystal is housed, and an outer shell to house it.
Instead of making the shell from scratch, it’s instead an amalgamation of several existing lightsabers that were remixed for this purpose.
Printing took much longer totalling 13 hours, but not all of that was for the final product you see on this page. Instead four hours went into test prints needed to make sure everything looked correct and would fit together, with nine hours needed for the main, final prints.
Some of the printed pieces required grinding to remove their supports and defects before they were painted and assembled.
The internal chamber needed some wiring for the crystal which were soldered in. This was put together first before the rest could be glued together.
Completed the printed measures in at 31 centimetres long, and 3.2 centimetres in diameter. Speaking of measurements here a two metre power cable is present here to provide power to the lighting.
While it would be expected that a battery would be used instead to make the print portable, say for cosplay, a cable makes more sense here if the project is intended to sit on a shelf as a display piece.
Those who would like to see a version with batteries inside will need to make it themselves using the files which are available for free over on Thingiverse.
Kruppe tells us that the project ate up 25 hours overall, but further versions made by the community should take less time with the files readily available and the instructions also provided in that link.