3D Printing

Saber Hilt Parts

Parts are designed to be 3D printed with FDM based machines. STL files are oriented to print "as is". Machines with dual extrusion or single extrusion setups are listed below with parts name and description. Parts require tight tolerances that might need adjusting slice setting. Reference the suggested settings below.

Hilt Dimensions

Use these numbers to reference if these parts will fit on your 3D printer.

  • Inner Diameter: 40mm
  • Outer Diameter: ~50-60mm
  • Full Length/Tall: 12in (30.4cm)
  • Build Volume: 50mm x 60mm x 90mm

Dual Extrusion Parts

Parts that can be printed with multi-material setups are labeled with an "A" and "B" suffix. Machines with multi-material setups will need to be configured using their own software tools for slicing parts. The parts in this project were 3D printed with Ultimaker 3 and sliced with Ultimaker CURA 3.X. 

fwls-emitter.stl

Blade emitter holds polycarb tube

fwls-barrel.stl

Barrel houses the circuit board retainer.

fwls-clamp.stl

Attaches to barrel and battery holder. Houses 2x 16mm panel mounted pushbuttons.

fwls-powercell.stl

Stores the 4400mAh power cell.

fwls-pommel.stl

Houses the 40mm speaker. Screws onto the power cell holder.

Single Extrusion Parts

Single extrusion parts are labeled with "single" as the suffix. These parts were merged for 3D printing with a single extrusion machine. Additional post-processing can be done after printing.

Additional 3D Parts

These pare are separate from the hilt and can be 3D printed with any extrusion setup. 

fwls-feather-mount.stl

Mounting bracket for the Adafruit Feather.

fwls-wing-mount.stl

Mounting bracket for the Adafruit Prop-Maker FeatherWing.

fwls-blade-cap.stl

Press fits onto 1" OD polycarbonate tubes. Use translucent PLA material for best light diffusion.

Parts Assembly

This animation demonstrations how all of the pieces are assembled to form the hilt. The emitter screws onto the barrel. The clamp attached onto the barrel and power cell. Pommel screws onto the bottom of the power cell. An M3 x 16mm screw and nylon lock nut is inserted into the clamp and secures the assembly.

Slice Settings

Use these settings as reference. Values listed were used in Ultimaker's CURA 3.X slicing software.

  • 0.2mm Layer Height / 0.4mm nozzle
  • 0.38mm Line Width (inner & outer widths)
  • 60mm/s printing speed
  • 20% infill

Glitter Infused Filament from Fillamentum

The material used to print the parts in this project are from Fillamentum. From the PLA Extrafill line of filaments, Vertigo Galaxy PLA,  Rapunzel Silver PLA, and Vertigo Gery were used. Material comes in 2.85mm and 1.75mm diameters. 

Dry Fit Parts

The pommel and emitter parts feature threads that tend to have tight tolerances straight off the 3D printer. These parts may need to be dry fitted a few times to loosen up the tolerances. Gradually fasten the parts by twisting them together. If needed, a filing tool can help smooth out the edges.

What If I Don't Have A 3D Printer?

Not to worry! You can use a 3D printing service such as 3DHubs or MakeXYZ to have a local 3D printer operator 3D print and ship you parts to you. This is a great way to get your parts 3D printed by local makers. You could also try checking out your local Library or search for a Maker Space.

This guide was first published on Oct 31, 2018. It was last updated on Oct 31, 2018. This page (3D Printing) was last updated on Jun 17, 2019.