Lightsaber MK III

The MK III aka the Serin Fel v3, my third Blender lightsaber, modeled after my personal lightsaber that I machined from aluminum once upon a time. I wasn't able to do the lateral cuts in the Grenade section when I machined the original parts (don't have a mill), whereas this is closer to my original sketch. Someone offered to buy my prototype years ago, and I haven't had a version of this hilt since. Now I can 3D print the parts whenever I choose, and so can you.


The parts on this guy are all manifold and ready for printing. The coupling surfaces are the same as the MK II making it so the parts could be swapped between the two, and a 1.25" OD aluminum core tube can also be used. The tolerances are pretty tight (or were on the MK II) for a slip/snap fit, so I have not included holes for set screws. I also plan on gluing some sections since I don't want to use set screws or retention pins. If I rig this for electronics and a 1" OD blade, I'll end up just drilling and tapping a hole for a blade retention screw, and I advise you do the same.


Disclaimer: I have not printed these parts yet, so I do not know for sure if the knurled effect on the Emitter and Pommel caps will print correctly. Minimal supports are required, a support angle of 70-80d with "touching build plate" in Cura ought to be enough [for most parts] to keep supports from getting out of control. Infill density is your choice; 15% works for me. The button still has the scaling issue in Cura. Uniform Scale X to 7.34 mm should fix it.

UPDATE: 11/17/2020 2:20 PM

Another problem with Grenade section fixed.

Grenade update printed. 6am, all excited. Go to assemble parts--Grenade male coupling surface too small. WTF?! Somehow, in the seventeen times I remodeled it, that section ended up smaller and I didn't compare it with the coupler. That has been fixed. Gah...


UPDATE: 11/16/2020 4:30 PM

Problem with Grenade section fixed.

Remodeled the Grenade section three times before I realized the lateral cutter was off and that was causing a non-manifold issue. I re-aligned the square rods used to cut the V groove up the length of the grenade, problem solved. Everything should be good now.


UPDATE: 11/16/2020 1:23 PM

I thought I had updated my boolean to cut the female coupling surface on the Emitter, Control, Grenade, and Pommel surfaces. I didn't. (Crap!) I just corrected that and uploaded the correct files. Still working on the Grenade remodel. At least the female coupling surfaces will be right now... grumbles something about wasted filament

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