I've always wanted to design and fabricate my own lightsaber hilt. My first idea, an aluminum hilt turned on a lathe, proved to be too expensive. Good thing I worked at a rapid prototyping lab!
As with every print, I made a test print to determine how much I needed to adjust my dimensions for variance. After that, creativity could run wild! I took inspiration from the lightsabers wielded by Obi-Wan Kenobi and Darth Vader.
I designed the lightsaber so that everything could be assembled together, instead of one giant print. This solves the problem of build space and overhanging prints.
After assembly and surface finishing, I poured a silicone mold. With some breather tubes and a pour spout cut, the mold form was ready for a resin pour. My first pour had too many bubbles; the second one used a vacuum chamber to eliminate them.
Ask me about:
- the importance of test prints
- working with low-resolution printers
- my job at RapidTech
- designing a product for post-print assembly
- working with silicone
- the resin I used for the final product
- surface finishing
- why I never painted it