Grey Jedi Saber Mk1

Last crawled date: 4 years, 2 months ago

Decided to build a custom saber over the holidays and so far things are looking okay.
This basic saber is modelled in Fusion 360.
The electronics are the Adafruit Feather M4 Express with the Prop-Maker wing.
These attach to the two printable cradles, which in turn fit in the Wrap.stl (main grip). It's a tight fit past the inside threads, but they do fit. There are two cradles; one has a large central cutout for an 11mm slide power on/off switch (for turning the electronics on). the second has two notches which will allow power wires to connect to the battery housing.
The power is supplied from a 18650 3000mAh 3.7v Li-ion battery, in a standard 18650 single battery holder. This also fits in the wrap.stl (grip) inline with the Feather/Wing and closer to the fore grip. Currently there are no cradle files for the battery. This will likely change if battery rattle becomes an issue (or I build a crystal chamber).
The sound is projected from a 40mm 4ohm 3w speaker, which (should) push fit in the pommel. (Disclaimer - on my initial version this worked fine. However, at some point I changed the thread size/pitch and my second print was way too tight. I have since gone back to what I think was the original thread size and that is the file I have included here. Once I have had a change to reprint the pommel, I will amend those files as necessary.)
The saber activation switch is a 16mm momentray push switch in the fore grip and this is a tight push fit and doesnt really need a securing nut on the inside.
The initial light source is a 7 neo pixel 5v (25mm diameter) spot which fits in the recess on the emitter. This will at somepoint be replaced with a poly carbonate blade but I need to buy some 144 LED neo pixel strips. At that point I will add another file for this blade emitter so that they can be swapped out.
All the parts are designed to be a screw fit and I have tolleranced the threads (+0.2) for my Ender 3 printer running Cura 4.4.1 on Low Quality (0.28mm) using Prima Value PLA. The connections are tight but not too tight (which was an issue before I added the extra 0.2mm offset on one half of the thread pairs).
I have had all the electronics and plastic together and everything works great.
I'm currently printing the Covertec belt clip and pommel clip and will hopefully re-print the wrap and pommel (if my PLA lasts).
The final .stl file is for a double coupler, which should allow both my prints to connect together (yes I am making 2 sabers, because... why wouldnt you?).
EDIT: I will be uploading a revised version of the cradles and the wrap .stls (marker _v2). This will include a groove locking mechanism for the cradles as I'm getting frustrated with the boards rotation when I'm turning the main power on and off. Also a hilt without the wrap for those wanting a plain hilt to add their own texture to.