3D Printed Lego Lightsaber With Collapsing Blade

This is a guide to how I created my lego lightsaber with a collapsing blade for 3d printing. I had an idea to create a remix of the collapsing blade lightsaber project on Thingiverse created by 3dprintingworld. I used Fusion360 to design the model, but this can be done in any 3d modelling software.

First, I recreated the lego lightsaber based on some reference images, then I scaled it up and made some changes to the model so that it could fit the blade of the collapsing blade lightsaber project.

Lego Lightsaber: https://www.thingiverse.com/thing:5379989

Collapsing Lightsaber: https://www.thingiverse.com/thing:3606120

Create Sketch

To start, I created a sketch of the profile of the lightsaber based on an image I found on the internet. I was able to import the image into fusion360 as a canvas so I could create the sketch on top of it. The lightsaber is made up of different sized cylinders so it's simple enough to create the profile. I added a line down the middle of the sketch to use as an axis to revolve around to create the solid model.

Create Solid Model

The lightsaber is cylindrical, so now the model can be created from the sketch by revolving the sketch around the centre line. Then, I created a new sketch for the slanted details on the bottom of the lightsaber.

Scale the Model

The lightsaber has to be big enough to contain the collapsed blade inside it, so it needs to be scaled up. I imported the blade STL from the collapsing ightsaber project into Fusion360 as a mesh. Then, I scaled up the model enough so that the thinnest part could contain the blade while having 2 millimetres extra either side for the walls of the lightsaber. I hollowed out the model to allow the blade to fit completely inside and separated the end to create a cap. This allows the blade to be printed separately from the handle and inserted or removed at any time.

Finished Model

And there you have it! A 3d modelled recreation of the lego lightsaber scaled up to fit in your hand and contain a blade that can be extended with a swing of the handle. It'll make you feel like a real Jedi... well, a real LEGO Jedi...