First of all I have to thank this board for all of the great information and inspiration. I have lurked for the past few months during this build and this forum has helped me tremendously. I wanted to make a couple of custom sabers for my two nephews (5 & 7) both of whom are star wars fanatics. I also decided that I would need to prototype one to work out the kinks, which I will be keeping for myself . I designed the entire saber in Solidworks, less the wiring. Once I finish up the drawings and assembly instructions I plan to post it all on grabcad. I also have a mostly complete bill of materials with sources and part numbers/prices if anyone wants it.

Same design x 3.
#1 is Blue with White FoC
#2 is Green with White FoC
#3 is Amber with Red FoC.

Nano Biscotte V3 sound board
Rebel Led
tri-star MCPCB
MHS Heat Sink V3
18° tri-rebel optic
28mm Bass speaker
18650 Battery
712A recharge port
Ĝ1.0 x .125" wall trans white polycarbonate tube
White shouldered blade tip w/ reflective tape
16mm sst antivandal switch (short)
7P Tyco pcb header
7P Tyco connector & pins
JST connectors
28 awg control wire (multi colors)
3D printed internal chassis
3D printed kill key
3D printed blade plug (not shown yet)
Machined aluminum hilt, switch plate, pommel, and blade holder.

Brainstorming


Design


Design


Machined Parts




Adding header to PCB





Soldering LED Star




Starting electronic assembly


LED Wiring



Thermal Tape



Resistors


Finished LED Assemblies


Optics



Speaker wiring


More boring wiring – JST connectors, etc


Testing



Some finished pics