Ezra Bridger's 1st Lightsaber

Just in time for May 4th!  This is my take on Ezra Bridger's first lightsaber.  Like my other models, this designed to be put together right from the build plate.  All parts are threaded or captured to make assembly easy.  This will also allow you to replace broken parts should your child sneak into your office on a Saturday morning while you are asleep, grab your prized model that you spent days printing, and snapping a piece off that you cannot replace because you super glued the hole thing together.  The pictures attached are as they came off the printer - no post processing has been done other than snipping of some PLA wisps.  

I try to make my models easy for others to print when I am designing them (It actually takes longer than designing them) but this one was an exercise in patience and I learned about the expansion properties of different PLA brands and colors.  I have dialed in my printer very well for dimensional accuracy… but that all goes out the window when you stack 19 washers on top of each other.  A section of washers that would measure 65mm now measures anywhere from 63 - 67mm!  So, I incorporated those extreme tolerance changes in this saber design as best as possible to guarantee a good print.  

***On a side note (after printing 80+ washers) I settled on using Sunlu Silk Black PLA and Ziro Silk Gray Silver for the washers.  The tolerances seem consistent between these brands and I was able to get an accurate measurement.

That being said, my suggestion when building this is to do the following.  First print the hilt, grip washers (top washer, bottom washer, grey washers,black washers) and the pommel.  Stack the washers on the hilt, followed by the pommel.  If the bottom of the pommel sits 1-2mm past the end of the hilt(not including the threads), you are all set.  I have designed this to work even if the Pommel goes 3mm past the end of the hilt.  HOWEVER, if the pommel comes up short to the end of the hilt, you will want expand the top and/or bottom washers in your slicer to make up the difference.  I hope this makes sense and feel free to reach out to me if you have questions or get stuck.

Assembly notes:

• I try to avoid supports but it was unavoidable with this design.  The receiver will need supports were the receiver screw sits (to connect it to the hilt) as well as the bottom hex section of the hilt (that connects to the receiver).  I am working on a completely support free parts but that will be updated at a later date. 
• You will notice I added notches to my threads where needed help with overhangs on the threaded holes (and eliminate the need for supports)
• For those of you who would rather not go through the hassle of printing 19 washers (I get it), I've included a solid piece that will need supports in the ‘Extra Parts’ folder
• For those of you who are OCD like me and want to ensure that the details on the end cap are clocked correctly, I have added a 3 part end cap assembly that is also in the ‘Extra Parts’ folder.
• You will need a flat head screw driver to install the receiver to the hilt as well as the D-Ring assembly to the pommel fork.
• I have added a 4mm hex to the barrel and receiver bolts to aid in installation.
• All parts have been positioned to hide the z seam where possible.
• Refer to the Pictures for assembly instructions

Print Settings

• Everything was printed at 0.15mm on a 0.4mm nozzle
• 3 walls
• 15% infill (I use gyroid)

Filament Used

• Sunlu Silk Black PLA
• Sunlu Silk Green PLA
• Sunlu Silk Red Copper PLA
• Ziro Silk Silver PLA
• Ziro Silk Red PLA
• Zira Silk Gray Silver PLA
• Overature Matte Black PLA

Final notes - this saber was a lot of printing; it's more like printing 2-3 lightsabers but it was a fun project.  Total weight (not including support material) is 320g.