This is a system that I designed for creating components for custom lightsabers. It was designed so that all of the different parts can be 3D printed fairly easily while still having a large internal volume to store the electronics and batteries for the saber. in general these internal volumes are around 1″ in diameter this size accommodates many of the control boards that are used in the hobby saber space along with the various types of power. Whether that be a 18650 Lipo cell, or a quad AAA housing, the 1″ is ideal for housing the internals to actually get function out of the sabers. All of the parts have a 2 inch length increment, this was done so that any of the pieces that are small enough can fit into the more complex accent pieces like an inquisitor or Ezra Bridger type of saber.

The basis for the system is a custom screw joint. This joint has very shallow and wide threads especially when compared to a standard screw. However this is needed due to the desire to make this a 3D printable solution, while fine threads can be printed with some success a wider and less complex thread has a much higher chance of success on most printers. All of the parts that were designed for this builder system are compatible with this simple screw design and were made specifically to be connected in ay order with them.

The parts for the system are divided into 5 different categories, Emitters, Accents, Switches, Grips, and Pommels. To get a better idea of what these pieces mean I will use the Skywalker hilt pieces as examples.

Emitters

These are the pieces where the blade would actually be coming from on a real saber, it emits the blade. The emitter here seems like it could have been simplified, however the placement of the round accents would have made that difficult this paired with the fact that the screw is around 3/4 of an inch means that there needs to be around 3/8 of an inch to add the threading to the piece.

Accents

Any pieces that are more for style than anything else, they could be eliminated without affecting the use significantly. On the Skywalker hilt it is about as simple as it gets, just a straight cylinder to connect the switch to the emitter.

Switches

Pieces that have some kind of button or switch that when pushed or activated would ignite the blade. The Skywalker hilt uses a slide type button, the rectangle encased in the part the prorudes from the main base slides up and presses a button to ignite the blade.

Grips

The main piece that is able to be held when wielding the hilt, providing leverage when in use. A very recognizable grip pattern on the Skywalker hilt. A cylinder that has 6 protrusions to increase the ease of gripping the hilt.

Pommels

The bottom cap of the hilt, serves the same function as a pommel on a sword. Caps off the bottom of the hilt and holds everything together. The pommel for the Skywalker blade is also very simple like the accent piece this one has cutouts so that the sounds from the boards can escape.

With these 5 components I have designed out many canon sabers and have created many from my own ideas or inspired from other media.

The canon sabers that have been designed for the system are as follows: