Well, after a year or so, here's my project! Still a work-in-progress but it's coming along.
I moved from a 2D CAD environment to a 3D modelling one. I revisited a lot of my earlier designs and concepts, improved manufacturability, made some changes, and this is the result. These have been built up in UGS NX4 Computer-Assisted Design/Machining/Engineering under my school's license, and rendered in a trial version of Autodesk Inventor.
Single-Bladed:
http://daveluck.deviantart.com/art/D...ured-103429454
Double-Bladed:
http://daveluck.deviantart.com/art/M...aber-103429615
The internal dimensions are as follows:
8.11" x 1.27"(dia) for the insides of the body. This includes clearance for a nut that holds the spike or the other saber.
1.78" x 1.00"(dia) for the inside of the emitter, for holding the blade.
There are some drawings on the site, but they are currently out of date and need to be updated. I will do this as soon as I can.
Hopefully this should be enough room for the internals; four AA batteries, the core, LED driver, and the power bar, recharge port, rumbling motor, and two buttons. Ten inches, not counting the spike is a comfortable length for me, although I have been working on another design that adds an extra two inches to the pipe that forms the body, and more or less if need be. I'm still trying to plan the installation, so we'll see.
Total weight is expected to be ~2.84lbs. The body is 6061 Aluminium, but the emitter and end cap are T-316 stainless steel (but this may change to 4140 alloy steel, as the plating makes stainless unnecessary) and the 'brainsticker' spike is heat treated 4340 alloy steel. The body is plated in Chrome Nitride for visual appeal and to increase superficial hardness, and the rest of the parts are plated with Titanium Carbon Nitride. The machining will be done here at the shop, the plating is being outsourced. If I can't get the plating done, the spike will be stainless as well. It will certainly be quite hefty and have a lot of weight.
Thoughts? Advice? This will be the first illuminated lightsaber I've made.
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