Custom Light Saber JLS

Project JLS is a custom light saber to complement my first design, this time with more of a light side inspiration.

I spent more then a year slowly working on this design to get all the features to work properly. This model has around 140 parts and can be made using a printer with a relatively small build volume.

Features of this light saber include:

• Removable power cell
• Lights to illuminate the crystal
• Removable side paneling for display
• Multi position emitter head changeable with thumb switch
• Belt clip and Lanyard loop
• Compartment in the pommel cap for small parts or hiding stuff

In the download you will find a full set of instructions with detailed assembly diagrams, complete bill of materials, project notes, material source list, and additional printing and assembly tips.

If you want to build the display stand I designed for this it can be found here.

You can also find a collection of belt loop holders compatible with both my light saber designs here.

Notes:

• Please refer to JLS_Instructions_Rev1.pdf in in the download for detailed instructions with diagrams, print setting for each part, and sources for purchased hardware.

The project was modeled and the exploded diagrams created using Siemens NX12. There was a lot of iteration in this design and NX made it very easy to test ideas with the linkages with out needing to build them all.

After the trouble I have had with wiring in the past I wanted to make this light saber easy to wire. So there is ample space in the mid frame for electronics, I just used simple LEDs but it should be big enough for a small PCB.