Blade V1.3 - Modular Lightsaber

This blade is part of a customizable lightsaber ecosystem where you can mix and match with other sets from my Build Your Modular Lightsaber collection. Originally made to work with the plastic lightsabers from the Disney parks, I'm taking it one step further so you can 3D print the entire lightsaber for play or display. I will be regularly adding new sets to create an expansive collection of lightsabers from both the movies and games.

V1.3 Update (3/21/25): 

1. I have added a shoto style blade that just so happens to be the perfect dimensions for the A1 Mini at 170mm tall! What a coincidence right???? (😉😉😉) It's perfect if you only have an A1 Mini and would like a strong blade or want a slightly shorter one for our younglings to get their bearings with. Here is a size comparison of the two side by side.

   

2. Custom brim added to segment 2, 3, and the tip to improve bed adhesion and print stability. I had every other print fail due to a piece falling over towards the end of the 8 hour print. The custom brim has small sprues that can be broken off easily and cleaned up with a razor blade or deburring tool easily if even necessary. In case you would like a blade without the brims, I have left the V1.2 STLs up for your use. Use them at your own risk and discretion.

V1.2 Update (2/1/25): I have altered the geometry on the cap and base segment to improve strength and fit inside the emitters. The changes are as follows:

• Added fillets at the sharp corners to reduce chance of layer separation on impact
• Increased flange diameter to spread out stresses and improve surface contact with emitter and hilt core
• Increased the base segment outer diameter to have a slight press fit inside the emitters to spread impact stresses away from flange

I HIGHLY recommend printing out of PETG or ABS as my two PLA blades have since broken at the base.

For some sleeves for your lightsaber, check out my other Build Your Own Lightsaber collection!

Enjoy and like and leave a rating!