Star Wars Rebels - Kanan's Lightsaber

thingiverse

Star Wars Rebels - Kanan's Lightsaber Recreating I made this as a commissioned piece for a cosplay costume back in December. After talking with my client on it we have decided to release it to Thingiverse. See my Blog for more details on the design and printing of this piece. https://fabricatingrealityblog.wordpress.com/ Print Settings Printer: Flashforge Creator Pro Rafts: No Supports: No Resolution: 0.2 mm Infill: 20% Notes: In total 19 pieces, printed it in PLA filament. Print speeds between 40 and 60 mm/s for best results. 20% infill on all but the smallest pieces (which for size reason are printed at 100%) Total parts print time for me was 19.25 hours using about 85m of filament (slightly less than a quarter kilo.) How I Designed This I designed this lightsaber replica off of screen captures for the Star Wars Rebels animated series on Disney XD. I worked from the stylized proportions and scale and did a lot of eyeballing to get the correct look and feel, I still feel like it is a bit long and maybe too fat but I am pleased with the results. I used simple polygonal modeling in 3ds Max, and ProBooleans to cut the pieces, a general tolerance between pieces was made to be about 0.2 to 0.4 mm and each interface between pieces is unique so it can only be assembled one way. Destructions Files Labels with 00 are inlays and detail pieces. Print one of each of stl files provided except for 00c-Kanan-MagneticChoke_x2.stl wihich requires two copies to be printed and 00e-Kanan-GribRib_x7.stl which needs seven copies. Assemble by gluing Pommel - Haft Bottom - haft set pin - Haft Top - Magnetic Stabilizer - Neck Bell - Blade Emitter together. After gluing install the grip ribs and face, glue. Finally install the rest where they fit. Grip face my need some alteration after printing for the emitter trigger to fit right, this area has an unfortunately tight tolerance.