Darth Malgus' Lightsaber

This was requested by one of my followers and it peaked my interest.

This is Darth Malgus's lightsaber first appearing in the StarWars: The Old Republic game. I based this design off of a few images online, and some Old republic trailers. This hilt is a behemoth coming in at around 15" (380mm) long and about 180g of filament. I was going to color the blades (black with a silver bezel) but it got a little ridiculous in the amount of filament it would have wasted. Still - if anyone wants the two colors - let me know and I will set up the part.

 

Like most of my designs, this hilt is designed to print and play. All parts are screwed in or interlocking; you will not need glue. I have set the seem lines to be as hidden as possible and plate 1 has been set up by object to save on time, filament swaps, and to keep the grip section steady due to it's height.

 

DESIGN UPDATE (10/15/24): A few of you reported issues with the blade tabs snapping with installing them.  I made the tolerances close (maybe a little too close) but didn't have this issue when assembling it.  After trying a couple different silk filaments, I was able to reproduce the issue.  So I have made some updates that should correct this issue.  (I also added some design details to the blades).  

Second - I originally wanted dual color blades to match the original design but the amount of filament and the time it would take was just too much to justify it.  After some (a lot) of testing, I have come up with a two color solution where the silver edges snap into the blade.  You will see to optional plates in the profile for printing these blades.  

 

A word of caution before you get started. All of the parts are press fit and threaded. SILK PLA is very brittle and weak compared to regular PLA. When you are assembling this saber, I would suggest you oil the threads a little to reduce friction (knife oil, gun oil, motor oil, mineral oil, ANY OIL). For the upper assembly with the blades, I sprayed everything down with ammonia free glass cleaner - it makes things slide together easily (and easy to clean up).

 

Filaments used:

• ZIRO silk PLA -Red
• ZIRO silk PLA - Silver Black
• Sunlu silk PLA - Gold
• Elegoo PLA+ - Black

Notes:

• Supports used on pommel and axe blades.
• Brims have been set on the activator parts (due to a couple thin walls) and the grip (for stability)
• Smooth PEI hot plate recommended.
• Refer to the attached pictures for assembly.

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