This story contains spoilers for Star Wars: The Rise of Skywalker
At the end of the latest Star Wars we see Rey (Skywalker) wielding a new yellow lightsaber. Not only has this weapon already been 3D printed, but it has been 3D printed complete with a mechanical assembly hidden inside.
The maker behind this project, Brad Harris, describes it as such: “This design features a simple mechanism in the top that allows you to rotate the Activation Gear and raise up the Emitter Teeth on top.”
Harris tells us that modelling the here was done mostly in Rhino. As the lightsaber was on screen for just a few seconds, and high quality home versions of the movie aren’t available yet, some creative licence was needed here to fill in missing pieces of the design.
As the leading theory right now is that the lightsaber is based on the staff Rey has been carrying since the first movie of the sequel trilogy, that was used as inspiration here.
Because of this the outside “aesthetic” parts of the hilt were relatively easy to make and only took around three hours to complete. The inner mechanism, on the other hand, took eight night’s worth of work to make going through various variations and test prints.
With the final model completed printing took around 20 hours to complete, which is not that much given the relative size here.
At its longest points the lightsaber is 12 inches long and 2.2. inches wide. That’s 30.48 centimetres and 5.58 centimetres for the rest of us outside of the US.
For finishing Harris started off with some Rust-Oleum filler primer and a thin layer of black acrylic paint as a base.
This was followed by various colours from Games Workshop whose paints are usually seen on Warhammer / 40K miniatures instead of 1:1 scale replicas like this. A layer of Ironbreaker was applied followed by a wash of Agrax Earthshade.
Dry brushing followed this, also using paints from Games Workshop. Necron Compound was applied to the edges for a worn metal look and Ryza Rust in certain spots for, well, a rust effect.
Two versions are available when it comes to the grip. A “bare” variant is there for those who want to wrap their print in real cloth, and another that feature a sculpted cloth instead.