Thermoformed Light Saber | May The 4th Be With You

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Celebrate May the 4th with a fun, functional, and highly customizable thermoforming project!

This Lightsaber-inspired container combines a detailed 3D printed handle with a thermoformed mesh capsule, perfect for holding candy, small gifts, or even LEDs for a glowing effect.

Designed with both aesthetics and practicality in mind:

• The handle prints cleanly with no supports
• The mesh insert is optimized for thermoforming
• The system uses a simple snap-fit / press-fit assembly

Perfect for:

• 🎁 Party favors
• 🍬 Candy holders
• 💡 LED light props
• 🧪 Learning thermoforming

⚙️ Features

• Modular design (handle + insert)
• Multiple color variations (mix & match!)
• Lightweight but sturdy
• Optimized for fast prints
• Beginner-friendly thermoforming geometry

🧰 Print Settings

Handle (Main Body):

• Layer height: 0.2mm
• Infill: 5%
• Supports: ❌ Not needed
• Material: PLA / PETG

Insert (Thermoform Mold):

• Infill: 30%-40%
• Material: PLA (recommended for shaping)

🔥 Thermoforming Guide (Simple Method)

1. Print the insert mold
2. Heat plastic sheet (PETG or PLA sheet)
3. Press over the mold (manual or vacuum forming)
4. Snap into handle

💡 Tip: Use thin PETG sheets (~0.5–1mm) for best results

🎨 Customization Ideas

• Transparent colored blades (like your red/blue/purple variants)
• Add LEDs inside for glow effect
• Scale length for mini or “double saber”
• Swap mesh density for different looks

IMPORTANT

If you are using a slicer other than Bambu Studio,  you need to configure the thermoform pieces (The ones called Form/Form(1)) correctly. In the Strength settings, adjust these:
 

The Infills in my profiles are as follows:
 

• Gyroid 30%
• Honeycomb 30%
• Triangles 40%