Lightsaber 3d-printing and casting-experiment, in a try to make a modular hilt system

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Detreut

Member
Hi guys!

I have been lurking here for a while, and finally descided to join!

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Above is my first homemade lightsaber hilt, heavily inspired by Starkillers. Manly made from copper tubing and a chromed stainless steel-tube, therefore being a relatively cheap project... when making this I had access to some heavy manufacturing equipment, but most of it was made by hand (the hunt for the mechanics in the middle was an absolute nightmare).

With this I aim to show that you don't have to buy ready-made parts or practically throw money at a lightsaber hilt, you can make up for a lack of finacial means by investing time and creativity!

A couple of years later, my girlfriend (who studies "Automation and Mechatronics") introduced me to a CAD-sofware used by Volvo called CATIA. I practically dissappeared for 3 days straight learning the nooks and crannies of the software, and I love it.

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This is what I first came up with... but deciding I had already completed the project, I moved on to make something more prequel-esc...

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This design is what I'm currently working on.. it's designed to be as comfortable as possible to wield and is made to be a prop without electronics, as well as to be used in the same fashion as the movie props. When I was happy with the design I moved on to get the parts printed, sanded and primed... the next step is making silicone molds of them and then proceed to cold casting them in iron, a field I have a really limited experience in haha! There are a few parts missing, but these will be painted in a brass color and are too complex to be molded and casted with the tools I have at my disposal. (I will also need to figure out how to mount them on a milling machine to enable the sanding of perfectly straight angles, as well as polishing them..)

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Advice for the upcoming nightmare would be appreciated, as well as any thoughts or advice for that matter!!
 
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