Lightsaber Hilt Proffieboard Core

thingiverse

Designed my own proffie core and hilt. Core is designed as 28mm diameter. Designed to accept proffieboard, 18650 battery and charging circuit. See my order from SaberBay for the BOM (picture). Not included in the BOM is 6mmx6mmx5mm tactile buttons (2x) or wire. The core has a built in support for the speaker housing. Print with speaker hole facing down and support should break right out. All other pieces print with blade side up except for the emitter. The one unique aspect of the build is that the blade is held in place via clamping force exerted on the blade when the emitter is tightened. The top and bottom portions of the design are held together by 3 M3x6 countersunk screws. no. 4 x 1/4" would probably work too. Note that while the hilt design is pretty solid, the core is a little rough on the design still. The hole for the 18650 battery is a little tight. I remedied this by using my soldering iron to 'sink' the positive terminal down in to the print to create an extra mm or two of space. Also had to open up the wiring channels from the battery terminals out the back with a drill bit to fit 20 AWG wire.