Custom Katana Lightsaber

3D print files for a custom katana-themed lightsaber.

** DISCLAIMERS**

1. This is NOT a beginner-friendly build. By downloading these files, you acknowledge that you are responsible for any damage or harm incurred in building or using this prop.

2. This prop is intended for display ONLY. Any damage or harm incurred by an attempt to use this prop outside of display purposes are your own responsibility.

3. These parts were designed with the intent to use an outside service to print them in SLS materials. Some experimentation may be required to get them to print on household FDM or SLA/LCD printers.

Still a work in progress, some things are missing

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Translations:

Tsuba - katana hand guard

Kashira - Katana pommel

Saya - Katana scabbard

Kurigata - part of the saya where the cord is traditionally tied

Kojiri - bottom end of the saya

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Build tutorial video here:
[put URL here later]

Tool List:

• ESD-safe soldering iron
• small metal-working files (smoothing machined metal and FDM prints)
• heat gun (heat-shrink tubing and vinyl work)
• metric hex wrenches
• wire cutters
• wire strippers
• hot glue gun
• small tweezers or forceps
• [PUT THREAD SIZE HERE] tap (switchcraft DC charging port)
• tap handle

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In order to follow along with the build video, additional hardware parts are needed.

Decorative M3 Counterbore Washers:
https://www.amazon.com/dp/B0BYPJ7THC?ref=cm_sw_r_apan_dp_N8W4T2TPPQWA4D6YEH21&ref_=cm_sw_r_apan_dp_N8W4T2TPPQWA4D6YEH21&social_share=cm_sw_r_apan_dp_N8W4T2TPPQWA4D6YEH21&starsLeft=1&skipTwisterOG=1&th=1

Decorative M5 Washers:
https://www.amazon.com/dp/B09KPDN2XN?ref=cm_sw_r_apan_dp_W4113X1B1GBEXVVC76PN&ref_=cm_sw_r_apan_dp_W4113X1B1GBEXVVC76PN&social_share=cm_sw_r_apan_dp_W4113X1B1GBEXVVC76PN&starsLeft=1&skipTwisterOG=1&th=1

M3 Knurled Brass Heat-Set Insert Nuts:
https://www.amazon.com/dp/B0C4GDBXML?ref=cm_sw_r_apan_dp_V95PZJSQDVDKEQN5P468&ref_=cm_sw_r_apan_dp_V95PZJSQDVDKEQN5P468&social_share=cm_sw_r_apan_dp_V95PZJSQDVDKEQN5P468&starsLeft=1&skipTwisterOG=1

M2 Knurled Brass Heat-Set Insert Nuts:
https://www.amazon.com/dp/B08T7NDPQC?ref=cm_sw_r_apan_dp_PRR7A0K8SJYC2B73YQ6W&ref_=cm_sw_r_apan_dp_PRR7A0K8SJYC2B73YQ6W&social_share=cm_sw_r_apan_dp_PRR7A0K8SJYC2B73YQ6W&starsLeft=1&skipTwisterOG=1

M3.5 Chain Link:
https://www.amazon.com/dp/B0B4N2FXHF?ref=cm_sw_r_apan_dp_FACRQA6CCBGB4EKAWF56&ref_=cm_sw_r_apan_dp_FACRQA6CCBGB4EKAWF56&social_share=cm_sw_r_apan_dp_FACRQA6CCBGB4EKAWF56&starsLeft=1&skipTwisterOG=1

Black Leather Ito Cord:
https://www.amazon.com/dp/B07F8JHXN2?ref=cm_sw_r_apan_dp_GM5BA7HXD6J0SK0Z3BC7&ref_=cm_sw_r_apan_dp_GM5BA7HXD6J0SK0Z3BC7&social_share=cm_sw_r_apan_dp_GM5BA7HXD6J0SK0Z3BC7&starsLeft=1&skipTwisterOG=1

Black/White Sageo Cord:
https://www.amazon.com/dp/B06XJ1MCPG?ref=cm_sw_r_apan_dp_9BBS0H339EBZ9N7MV42W&ref_=cm_sw_r_apan_dp_9BBS0H339EBZ9N7MV42W&social_share=cm_sw_r_apan_dp_9BBS0H339EBZ9N7MV42W&starsLeft=1&skipTwisterOG=1&th=1

White Grip Tape:
https://www.amazon.com/dp/B099P8821N?ref=cm_sw_r_apan_dp_MVZVWV1FVJW8KVXTXJE4&ref_=cm_sw_r_apan_dp_MVZVWV1FVJW8KVXTXJE4&social_share=cm_sw_r_apan_dp_MVZVWV1FVJW8KVXTXJE4&starsLeft=1&skipTwisterOG=1

8.2Ohm 3W Resistors:
https://www.amazon.com/dp/B07QLVPR3Y?ref=cm_sw_r_apan_dp_HJCBPSZXQ28N1KR1KNC9&ref_=cm_sw_r_apan_dp_HJCBPSZXQ28N1KR1KNC9&social_share=cm_sw_r_apan_dp_HJCBPSZXQ28N1KR1KNC9&starsLeft=1&skipTwisterOG=1

Wireless Guitar System:
https://www.amazon.com/dp/B0BQB6PSC2?ref=cm_sw_r_apan_dp_6JN5XNGKG4CPED59VSWE&ref_=cm_sw_r_apan_dp_6JN5XNGKG4CPED59VSWE&social_share=cm_sw_r_apan_dp_6JN5XNGKG4CPED59VSWE&starsLeft=1&skipTwisterOG=1

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TCSS Parts:

Emitter:
https://www.thecustomsabershop.com/Modular-Hilt-System-V2/Blade-Holders/MHSV2-Blade-Holder-Style-1

Extension:
https://www.thecustomsabershop.com/Modular-Hilt-System-V2/Extensions/2-Double-Female-MHS-V2

Battery:
https://www.thecustomsabershop.com/Electronics/Batteries-and-Packs/Li-ion-37V/DM-Keeppower-Li-Ion-18650-37V-15A-3000mAh-PCB-Protected-Rechargeable-Battery

Soundboard:
https://www.thecustomsabershop.com/Electronics/Sound-Modules/Golden-Harvest-v3-Phase-4-Sound-Module

Switches (x2):
https://www.thecustomsabershop.com/Electronics/Switches/Momentary/Tactile/SPST-Momentary-tactile-switch-P641

Charge Port:
https://www.thecustomsabershop.com/Electronics/Batteries-and-Packs/Clips-Connectors/Switchcraft-21mm-Power-Jack

NPXL Hilt-Side Parts:
https://www.thecustomsabershop.com/Blades/Pixel-Blades/Pixel-Blade-Components/NPXL-Style-Connector/1-NPXL-V3-Hilt-Side-Adapter

https://www.thecustomsabershop.com/Blades/Pixel-Blades/Pixel-Blade-Components/NPXL-Style-Connector/Pre-Soldered-NPXL-V3-Hilt-side-PCB-connector-Long-Pins

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Various metric screws will be necessary but I will list the lengths and head diameters instead of a specific link.

M3 Head Diameter:5.4mm:
1x 16mm length (kashira to tsuka)

M3 Head Diameter: mm:
2x 6mm length (kashira shroud)

M3 set screw:
1x 5mm (blade retention screw)

M2 Head Diameter: 3.8mm:
4x 12mm (tsuka to chassis)

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The two PDF drawings in the things files list show how to make parts inside the saber. The two TCSS parts go at the top of the saber chassis and allow the chassis to attach rigidly to the blade and tsuba. The screw anchor also helps with this. The screw anchor does not need to be machined out of aluminum, but I would recommend a metal material over a plastic material.

There was no room for a conventional speaker so sound is wireless with the guitar transmitter. The transmitter is housed within the hilt and powered on the same battery that powers the rest of the saber. The receiver can then be plugged into any speaker system to get sound out of it.

Blade is a pixel blade made using TCSS NPXL parts, but any pixel blade from other vendors should work as long as it is a 1-inch diameter. The max length that the blade can be and fit in the saya is 30 inches.

The handle and chassis files that end in "2" are updates that I made in order to strengthen the hilt and make it so that it would be possible to swing the saber without it breaking. If you intend to make this for display purposes only, the version 1 files are easier to build but you will not be able to swing the saber at all and if you do it is likely to break.

The V2 kashira files are there because some people didn't like the over-complicated kashira with a shroud that I initially made. The V2 files are simpler and more akin to what a real katana would have.

I did not include a link for the menuki because the ones that I used are no longer available. The part is easily searchable on sites like Ebay or Amazon so feel free to get whatever color/design you want or leave it out entirely.

The parts listed above will allow you to build the hilt exactly as shown in the build video, but creative liberties can be taken as desired.

Good ideas from comments to implement later:

• make a 3d file for the tsuka ito for people that want to print it instead of tie it

• make a wiring diagram for the electronics

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Release Notes:
V1: Initial release
V2: Button box and handle updated to add structural stability. Added new kashira for those that want a simpler design.
V3: Publish as WIP for people that want the files and don't need build video.
V4: 5/9/2025: Added PDF drawings of TCSS parts and machined aluminum part. Added TCSS links. Added part name translations.
V5: 5/12/2025: Added max length and diameter of blade. Added old pictures of internals.
V6: 5/17/2025: Added pictures to show how the emitter section goes together. Added MHSV2 holder for NPXL hilt-side PCB.