Lightsabers

These lightsabers replicas are modeled in Fusion 360 and then 3D-printed. They have been made with a dedication to look as accurate to the movie props as possible, such as including the iconic GRAFLEX engraving on one of the sabers.

Software used:

Lightsabers

These lightsabers replicas are modeled in Fusion 360 and then 3D-printed. They have been made with a dedication to look as accurate to the movie props as possible, such as including the iconic GRAFLEX engraving on one of the sabers.

Software used:

Lightsabers

These lightsabers replicas are modeled in Fusion 360 and then 3D-printed. They have been made with a dedication to look as accurate to the movie props as possible, such as including the iconic GRAFLEX engraving on one of the sabers.

Software used:

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Replicating the
original

To replicate the original props, a heavy research phase was required to learn how they were originally crafted.

Did you know…


The three lightsaber props used in the original film are made of seemingly random items like camera parts, british grenades from WWI, an assortment of electronic and calculator parts, and windshield wipers?

Did you know…


The three lightsaber props used in the original film are made of seemingly random items like camera parts, british grenades from WWI, an assortment of electronic and calculator parts, and windshield wipers?

Image: starwars.com


Image: starwars.com


Modelling

Fusion 360 was the tool of choice for this modeling effort, marking one of my initial ventures into CAD design and paving the way for future explorations in digital design tools.

perfecting the product

For me, the act of creating with my hands is therapeutic. Despite utilizing 3D printing for the base models, the project demanded a significant amount of manual handwork to achieve the desired authenticity.

  • First, the 3D-printer does what it does. If the files are prepared correctly, this should go relatively smooth…

  • Second, the prints need to be sanded meticously to get rid of print lines and achieve a smooth surface. Sandable filler helps fill any potential gaps.

  • Third, it's time for the electronics to go in. These sabers are driven by two chargable 3.7 V lithium batteries. Together with the ultra strong LED, it shines bright as day.

  • Lastly, the sabers are painted. A couple of layers black primer ensures that the paint sticks well, especially important when working with chrome spray paint.

  • First, the 3D-printer does what it does. If the files are prepared correctly, this should go relatively smooth…

  • Second, the prints need to be sanded meticously to get rid of print lines and achieve a smooth surface. Sandable filler helps fill any potential gaps.

  • Third, it's time for the electronics to go in. These sabers are driven by two chargable 3.7 V lithium batteries. Together with the ultra strong LED, it shines bright as day.

  • Lastly, the sabers are painted. A couple of layers black primer ensures that the paint sticks well, especially important when working with chrome spray paint.

Final Result

The lightsabers are 3D-printed in segments so that rechargable batteries, cables, switches and lights could be inserted before the final assembly. Both sabers have two threaded sections so that they can be opened up, which allows for battery recharge.

The blade itself is a high-quality, durable, frosted polycarbonate tube with a rounded tip that perfectly diffuses the light evenly along the length of the blade. The paintjob was made as accurately as possible to mimic the actual materials used on the movie props, those being aluminum, plastic, rubber and other metals.

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