Since we have a shiny new section for 3D printed stuff I thought I'd post this. It's something I've been working on for a while now. "Radiance" a small padawan saber I want to make for my son who is 8. I started designing it in Fusion 360, while I was working on finishing my tiny workshop, and thought hey I have a 3d printer I could actually print this to see how all the parts work out. so I did...
The Idea is to Machine this hilt after I work out all the details, and you know finish my shop.
here are the quick specs;
5 parts for the empty hilt
8" total length
1.375" OD on the emitter switch and Pommel
1.25" OD / 1" ID on the grip
here are the pics;
I did something crazy for the printed version, I added threads for the blade to be screwed on. I've never seen anyone else do it so I'm pretty sure there is a good reason for that... but I figured what the heck I'll give it a go. I'll most likely change this to a set screw on the bottom just above the shroud. I made the shroud with a lip so I don't need a screw to keep it in place. This also allows me to dial the orientation with the switches should my son change his mind on how he wants them to line up.
The LED holder and emitter are one piece so the heatsink screws directly into the emitter.
My son wants a two button setup but also wants an illuminated switch so I crammed them both into the 1.5" switch section which has a 1" ID. I also wanted to add a simple crystal chamber so I had to cut a notch in the threads to get it all to fit. The LED seen sticking out is an accent LED.
I don't have the bottom section of the crystal chamber printed out yet as I'm working out how I want to attach it to the chassis which I am currently working on.
This is a work in progress so feel free to leave feedback!