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Lightsabers, what are they?
Lightsabers, what are they?
They are elegant weapons from a galaxy far, far away.
What kind of lightsabers do we make?
What kind of lightsabers do we make?
As a club, we design and build custom model lightsabers. They are similar in quality to those found online for a couple hundred dollars. Ours are much cheaper though, since we only buy the parts and build them ourselves.
The blades are made of clear tubing with LEDs running along the inside. We have complete control over the color of the LEDs, and some boards allow for programming advanced custom effects and sounds.
What is the process?
What is the process?
We walk through the entire process from start to finish at club meetings.
If you are not a student, or are unable to attend some or all meetings, you may follow these steps and the rest of the documentation to the best of your ability. We are always happy to help and answer questions via discord or email.
Step 1a. Choose the Parts
Step 1a. Choose the Parts
There are a few key decisions to make when designing your lightsaber. The specific parts you choose will determine your lightsaber's capability, cost, and complexity to build.
Step 1b. Purchase Parts
Step 1b. Purchase Parts
VT STUDENTS
The club purchases everyone's parts as a group near the beginning of each semester. Each member will fill out a form selecting which parts they would like to add to the group buy. Once the form has closed, we will send emails to everyone with their individual cost due. The typical individual cost is around $140-160. Payment is due the week after the form closes. We will NOT order your parts if you do not send your payment in time.
NON-VT Students
We provide links to our vendors in the parts breakdown page. Reach out to us if you have questions on where to find specific parts.
Step 2. Design the Hilt
Step 2. Design the Hilt
Draw a simple sketch of your hilt. Plan out the rough dimensions and locations of key features. Experiment with various designs, have fun, and be ambitious. This is your opportunity to design a fully unique lightsaber.
Step 3. 3D Model the Hilt
Step 3. 3D Model the Hilt
You are free to use whatever CAD software you want. We teach OnShape in our workshops and use it in the examples.
SolidWorks, AutoCAD, etc. work fine, as long as you can follow the design criteria and export it as an .stl for printing.
Step 4. 3D-Print the Hilt
Step 4. 3D-Print the Hilt
We use generic PLA to print the hilt parts. PETG is also great for extra durability and use outdoors. We recommend using black filament to help the paint stand out.
VT-STUDENTS
We have a set of club printers that board members use to print parts for members.
Email parts to vt.lightsaberclub@gmail.com, subject name:
“F25 3D Printing - [First Name] [Last Name]”
Include a screenshot of your CAD model.
We will print parts and hand them out at the next meeting.
The sooner you send us your parts, the sooner they get printed and the sooner you can start painting them. Painting takes a couple meetings (weeks).
NON-VT STUDENTS
You will have to use your own 3D-printer or find a local library/makerspace with one. If you are in Blacksburg, Newman Library provides free 3D-printing services at the Prototyping Studio.
Step 5. Prepare Inner Pipe
Step 5. Prepare Inner Pipe
We use steel pipes with a 1 inch inner diameter for the inside of our hilts. The 3D-printed parts are glued around the pipe.
VT STUDENTS
Once the steel pipes have been ordered and cut to size, we will hand them out at club meetings. Mark the following on your pipe using your printed parts as a reference:
Button hole (Circle & shade the inside)
Blade Retention Hole
Any additional holes
Crystal chamber
Belt clip hole
Return your pipe once the holes have been marked to have them cut out.
NON-VT STUDENTS
You are responsible for purchasing and cutting your own inner pipes. If you do not have the tools to cut steel pipes, you may try other materials such as aluminum or PVC.
Step 6. Painting
Step 6. Painting
3D-printed parts require 3D-printed parts require a lot of sanding and filler primer to remove any visible layer lines and imperfections. After sanding, apply your spray painted design and finish with a clear coat.
Step 7. Electronics
Step 7. Electronics
After all of the parts have arrived, you may begin work on soldering and assembling the electronics. If you participated in a club group buy, we will hand out bags with all of your parts at meetings.
Step 8. Configuration & Programming
Step 8. Configuration & Programming
Follow the right guide depending on your soundboard to configure your lightsaber.
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