3D-printed first saber

[Mineral]

I 3D printed the details, pommel, shroud, switchbox, for my kid's otherwise pretty standard PVC stunt-saber (with switches, blades, and blade tips purchased from TCSS). It really improved the overall look and feel of the saber (IMHO).

The regular MakerBot filament would make brittle and breakable dueling saber bodies, but they make great detailed greeblies and ornaments. At the very least, I would recommend PVC as a blade holder. I've knocked some printed objects off of a shelf onto the tile floor, and if they have any weight to them at all, they can shatter. I would guess you'd have at least fractures after the first few blows of a saber duel.

If it's just to be pretty, then print away! Just make sure you buy the stuff you can't print from TCSS!

Yes, I do have the experience of using a CNC machine, but, since im out of work I dont have any machine to use that experience in XP. Thus, im looking for the possibilities of using a 3D-printer instead.

You can cut PVC with a sharp knife and some patience

[FenixFire]

As a product designer with extensive experience in prototyping and 3d printing, coming up on 15 yrs. If the printer is one of the very low-end hobby built systems like most public maker spaces I have seen, I would not attempt a hilt or blade holder. I would only attempted them on something capable of 100 micron layers or better, both for resolution and an increase in strength from my own experiences. I would also stick to printers capable of running true ABS materials over the more common PLA based materials. PLA is biodegradable and will breakdown over time especially with the bacteria and oil transfer from your hands. I have designed several PLA based pens that use that bacteria transfer as the initial phase of decomposing the material. Keep in mind even the manufacturing quality Fortus machines you get roughly 75% of the ABS's shear strength in your parts; so design accordingly. If designing a non-dueling sabre go for it. if looking to actually full speed dual...I would say good-luck.

[Forgetful Jedi Knight]

I understand.

But my point is still the same. This place (forums and store) are mostly for the parts sold here, and getting support for those parts (MHS, electronic or otherwise)..

And your point #4 is in-correct. It is NOT an open forum. It is a forum owned and operated by a person who has a store front attached to it.

It is -not- for talking about products in other places.
It is -not- for talking about other vendors. (especially those in direct conflict with the site/store)

I read your initial post as something like:


"Sorry I cant afford to buy stuff at TCSS, ... but still help me spend my time/money elsewhere."

If you have all the skill noted above, modeling, CNC..etc.. I dont quite understand why you would even go the 3D printing route.. unless it was for a internal chassis or something? I dont think you'll get any sort of decent quality for an outside/hilt piece that is done at a library type 3D printer... (but thats just my opinion.. you have the skills/experience)... quality on those type of printers would take many, many hours IMHO.. your best bet would be to get it done by a company like shapeways..etc (but thats expensive too)

if you can model it.. than your local makerspace probably has CNS lathe/mills too..

maybe that is a better [place for you to see help/advice?

Even therpf.com is better.. and more of the forum you are looking for. (open for said tech questions)


but hey, I'm not a moderator, and your post is still up/here.. you've been giving advice on where else to look.

good luck.

I am late to this "party", but I WILL reinforce what xl97 has said, as I am a Mod. This Forum is attached to and host by a store.

[FenixFire]

As for the parts in the store they are very reasonable, much cheaper than one could get the same parts turned and machined from most prototyping houses.

[xl97]

As for the parts in the store they are very reasonable, much cheaper than one could get the same parts turned and machined from most prototyping houses.

no doubt.

and quality!


and thats (again) thanks to the owner investment.

[FenixFire]

Like I said, its definitely possible, people been doing it increasingly frequently lately. My only concern is hilt durability if not 3d printing in metal...

If that were the case you could buy 3-4 complete builds for the price of one metal-fdm hilt.

[FenixFire]

well that was kind of a rude way to put it in my opinion...

1: I WILL buy a MHS saber, ASAP
2: Im adept in Solid Works and know how that program works, and therefore can design my own saber quite easy.
3: Im also adept in CNC-machining (the same principle in 3D-printing with G-codes and such) so if I had the possibility I've already done my own parts in aluminium and never searched after a Place like this at all on the internet.
4: I thought that this was an open forum for all lightsaber-lovers, and not just only for shoptalk.

I Think that I know at least 1 or 2 people on this forum that has at least concidered 3D-printing a hilt to at least see the design Before commiting to buy a saber. Now, what I wanted in this thread was to know if there were anybody that could help me a bit to make a good 3D-print and make my Dream of owning a good saber come true: I would STILL have to buy the Electronics from this Place (at least soundboard, blade and a few other small items) if I wouldn't go with HHCLS aproach and solder my own LED-string instead, which wouldnt be a too big of a problem for me, I love to build my own things.

Yours Truly Samuel G

G-code is antiquated when 3d printing. I actually haven't used it or any win cad based software in years. Any decent fdm machine will have the ability to print directly from solid works, pro/e, fusion, or most any other main stream software.

By the way; based on some biomechanics studies of bat and racket swings of the same motion as dueling, the force of impact could exceed 37000 newtons or 8400 lbs of force when full speed dueling. Potentially doubled (2 sabers impacting at equal speed) as that was the average force measured for a single bat/racket swing on ball contact.

[samthe0ne]

I am late to this "party", but I WILL reinforce what xl97 has said, as I am a Mod. This Forum is attached to and host by a store.

Okey, And Im sorry if I offended you guys with this matter, that was never my meaning. Feel free to delete the thread if you Think that it is too far out of Place.

[samthe0ne]

no doubt.

and quality!


and thats (again) thanks to the owner investment.

Oh, make no mistake I LOVE the quality here!!! And if the market wasnt so small here in Sweden/Scandinavia I would also love to put up a TCSS-shop/manufacture-line here (that would have been very fun) but I guess that it wouldnt be economical for the owners in the headquarters in US.

[samthe0ne]

G-code is antiquated when 3d printing. I actually haven't used it or any win cad based software in years. Any decent fdm machine will have the ability to print directly from solid works, pro/e, fusion, or most any other main stream software.

By the way; based on some biomechanics studies of bat and racket swings of the same motion as dueling, the force of impact could exceed 37000 newtons or 8400 lbs of force when full speed dueling. Potentially doubled (2 sabers impacting at equal speed) as that was the average force measured for a single bat/racket swing on ball contact.

Yikes... hmm, oh well, right now I dont have anyone to duel with, which makes that problem a bit smaller, but still...