Custom Cutaway Saber Hilt

I sometimes have electronics/hardware packs for the saber in my shop.

UPDATE 1/29/17: new simplified parts added for less assembly or easier prints. Includes: fatter, simpler cooling fins, pommel with gears and ridges integrated and one-piece manifold.  Focus crystal mount updated to v2 with a slot in the back for easier wiring.

Print Guide updated to v4 to reflect updated parts. 

NEW Assembly Guide v5 - more pictures, more in-depth, much better wiring process

WATCH Bill Doran of Punished Props and 3D Printing Nerd - Joel Telling - assemble and paint my saber.

Forge your own saber and be an apprentice no longer!

This is a custom cutaway saber hilt designed to print on the Form 2 SLA printer.  It takes advantage of the Form 2's high-resolution and multiple materials to make a piece that looks great right out of the printer.

The saber is designed to be glued together with the cutaway portions held in place via magnets.  The saber can be lit up with your choice of LED - with a rechargeable battery system hidden in the pommel. 

A print guide with recommended resins and settings, as well as a hardware list is included with the file download. Most of the parts look great at .1mm layer thickness and I have designed custom supports for most everything for optimal printing.

The PreForm layout files can be downloaded here.

The saber can be sanded and painted if desired - checkout Formlabs Finishing Guide.

See how to assemble the saber on Tested.

Watch how my cutaway saber was designed.

PHOTOS BY NORMAN CHAN