Ahsoka Tano - Rebels era Lightsaber handles

Replica of the handles for Ahsoka Tano's white bladed lightsabers from Rebels and The Mandalorian.

Design

This file has been split up to minimise the amount of supports and to allow printing it in different colours before assembly (to minimise finishing work). The pictures included have had no sanding or painting and are pretty much just printed, cleaned up and assembled.

Colour printing

If you want to print this in separate colours (rather than painting yourself) then you will need (with the brands I used in brackets)

• Light Grey (Filamentum Extrafil Electric Grey PLA)
• Dark Grey (Filamentum Extrafil Iron Grey PLA)
• Silver (Polyalchemy Elixir Lucid Pearl PLA, not the best choice but what I had)
• Bronze (Fiberlogy FiberSilk Metallic Bronze, looks dull on spool but prints shiny)
• Black (old spool from rigid ink, but they're now out of business)

Printing Guide

All parts have been pre-aligned for printing.

You will likely need to enable brim on a number of these parts, especially the larger handle parts which have very small contact areas.

While supports are not required on the majority of pieces, there are a few smaller pieces that do require supports and 4 pieces (2 per handle) that need bridge supports due to long bridges (these are used as glue surfaces, so while the bridges aren't visible they do need to be relatively flat to make a good surface to align things to). Where supports are required it's indicated in the file name.

Note: Bridge supports have to be enabled manually in some slicers (such as Prusa slicer)

I printed this in various PLAs in 0.1 to 0.2 mm layer heights (depending on part) with default infill settings. I did increase the number of perimeters for the large handle pieces to give some additional strength.

File naming conventions

The file name contains information on:

1. Whether the part is for the large handle or small handle
2. A part number
3. The colour to print (from light grey, dark grey, silver, bronze, black)
4. Whether supports and/or bridge supports are required
5. The name of the part

Assembly

A PDF document is included with basic assembly instructions.

In addition to the printed parts you will need two D-Rings. I used 30x20mm d-rings with 3mm cross section; any size should work as long as the cross-section is the same. Amazon sell these by the bag full for cheap.

Some of the glue surfaces are fairly small, that's my bad but it's too late to change, so you want superglue with a narrow or brush applicator. Take care when aligning the parts of the main handle or you'll end up with an ugly seam, other parts tend to hide alignment issues due to the way the handles assemble.

How canon are these

As good as I could make them. There isn't a lot of good reference material out there other than other peoples replica props (nice but not authoritative) and the Galaxies edge replica props (okay, but obviously designed around the need to support the electronics for the glowing blade so they aren't very accurate themselves). Rebels itself seems to go out of it's way to not give you as good a look as I'd like. The handles on the Mandalorian look similar, but it was hard to get a good look to see if they have changed much.

I've tried to do my best based on the material I could find with one exception: The power button on the small handle has been swapped to the other side. The official Galaxies Edge replica has them both on the same side, which makes no sense as you would want to use your thumb to switch them on/off which requires the buttons to be on alternate sides.

If you're thinking the main hand handle looks huge, you're right. The small handle is scaled correctly as best I can tell and then the large handle is basically just the same width/depth but longer. It's possibly my design is a little out (a few centimetres), it's also possible the whole thing is scaled a bit large due to my chunky hands, but it does seem to line up with what I could see in the recent episode of Mandalorian that showed them.