Jedi Lightsaber Wand

This is a (mostly) realistic version of Luke Skywalker's lightsaber from Return of the Jedi scaled down to 40% of original size.  The design is broken into multiple parts, letting you easily create a multicolored handle.  Parts are pre-sorted into color groups with a 3mf file.    

Why This Size?

This lightsaber ended up wand-sized by accident.  I initially scaled parts down to a keychain but realized that fully accurate details would be too small for FDM printers with a standard 0.4 mm nozzle.  (The thin sections of barrel and buttons on the side are the limiting factors.)  So, I scaled the design to a more manageable size that is easy to hold.  At 114 mm long, the parts for the handle are easy to print while retaining a lot of detail.   

Supplies

• 1/4 inch or 6 mm dowel rod
• Glue

I recommend using thick glue to hold all of the pieces in place.  I used quick-setting 2-part epoxy, but superglue gel should also work. 

If you want an accurate scale model, the dowel for the plasma blade + handle should be 19 inches (48.5 cm) long.  My lightsaber in the picture is a little short to suit my own preference.  Feel free to make the length anything you want.

If you want a fancy and strong lightsaber, you can use metal like brass or stainless steel for the blade.  I used wood dowels to keep the cost low.  Please note that cheap dowels may not have an exact diameter and can even have a flat spot or two.  Definitely sort through a few to find the best one, and have some sandpaper on hand to fix the high spots.  

Notes and Assembly

Print on a smooth bed surface for neat and tidy seams.

Parts are labeled A through K, with A at the top of the handle and K at the end.  I include labeled pictures and drawings that show the order and number of parts.  You will need 9 copies of F, and 8 copies of G.  Print part A first and test the fit with a dowel rod.  If the size needs to be adjusted, simply scale the part.  Remember to scale all the parts equally.  

If you want to simplify assembly with fewer pieces, I combined multiple pieces into two big sections: F_G_Part1 (located towards the top) and F_G_H_Part2 (located towards the bottom).

Parts are not symmetrical and require a specific orientation!  The raised ring on each part should fit snugly into the recessed groove of the adjacent piece.  This feature helps align the pieces and make them concentric.

Note that C and D are the only pieces that do not have a ring and groove where they touch.  Also note that parts C and F are very similar.  They are both the same color.  F has a ring and groove while C only has a ring.

I highly recommend that you line up the parts on the dowel before you add any glue.  Once you are satisfied with the assembly, start by gluing K at the end of the dowel.  Then keep sliding more pieces into place and adding glue.  

Thanks for visiting, and enjoy!