3D Printed Lightsaber!

Over the weekend, I started on a prop project from my all-time favorite Jedi Master: Obi-wan Kenobi.

Since the release of the Kenobi spin-off, I couldn't wait to make an Obi-wan inspired costume to use at Halloween. I was able to find a free set of STLs on Thingiverse: https://www.thingiverse.com/thing:1839833

This is the Episode 3 version, but close enough!

Good parts are shown on the left, with some spare/prototype parts on the right. This was printed in ABS for easier sanding/finishing. I will be sanding and painting, then assembling/gluing together. I'm hoping to accomplish a realistic metallic finish when complete, and then weathering the assembled saber. There were some issues, requiring a bit of prototyping:

Due to the orientation of the top emitter, even with support materials, the first version was very rough. I tried cutting the part in various parts in order to flip the part on the plate and get a better surface finish (moving left to right).

I found the furthest right version also gave a neat grid/mesh look inside the emitter, just as a bonus, unintended effect!

Well, that's progress so far. I'm not sure when I'll get onto sanding and painting, but stay tuned for part 2 of this post!

Thanks for reading!