Lightsaber Water Bottle

A few weeks ago, I was scrolling through TikTok when I came across a video of a guy showing off his Disneyland Lightsaber water bottle. Intrigued, I searched online and found that it was selling for USD 39.99. Instead of buying one, I decided to make my own using 3D printing. The Disneyland design was inspired by Darth Vader's and Anakin Skywalker's lightsabers, and I wanted to create something similar.

Using Tinkercad, I quickly designed the lightsaber. The challenge was gathering all the necessary hardware: lights, a water bottle, and the lightsaber sound effect. After some R&D and searching, I finally got the idea of how do it and ordered everything I needed from AliExpress. It took a while for the supplies to arrive, but now my DIY lightsaber water bottle is complete.

How it works:

When you open the bottle cap, a limit switch activates the LED. The light sensor then detects the LED light and triggers the greeting card sound module to play the lightsaber sound effects.

Difficulty level:

1. 3D printing - Easy
2. Assembly - Easy 
3. Wiring - Intemediate
4. Painting - Easy - multicolor 3d printing

So lets begin..

1. clear transparent water bottle 500ml - https://s.click.aliexpress.com/e/_onPfCZC
2. greeting card sound module - https://s.click.aliexpress.com/e/_mOHEPQU
3. Led light ring - https://s.click.aliexpress.com/e/_mMxiRY4
4. D ring - https://s.click.aliexpress.com/e/_EzqdEMJ
5. 7x12 mm Helical Compression Spring - http://shrsl.com/4mpvl
6. M3 brass thread insert - http://shrsl.com/4mpvg
7. M3 screws - 6mm, 12mm & 20mm - http://shrsl.com/4mpvj
8. M2 screws - 5mm - http://shrsl.com/4mpvh
9. 2mm x 25mm Stainless Steel Dowel Pin - http://shrsl.com/4mpvk
10. Aluminium rod - 4mm & 6mm diameter
11. limit switch

And of course a 3D printer.. i'm currently using a BambuLab A1..

you can get any of the supplies here using my affiliate links if you're interested..

After receiving the water bottle, designing the lightsaber around it was straightforward. I've included an electronics box on the side of the lightsaber, just like in the movies. The box fits a greeting card module and a 3xAAA battery, which can be easily replaced.

The water bottle consists of three parts:

1. The body
2. The top cap
3. The bottom cap

The clear water bottle is inserted from the bottom and secured with screws.

I designed the lightsaber so that no 3D-printed parts touch the water inside the clear bottle. With the cap at the bottom, you can easily remove the clear bottle for cleaning without getting the lightsaber casing wet.

I added channels for the wiring and for the water bottle to fit into the 3D-printed lightsaber parts. These channels allow condensation to slide down to the bottom of the lightsaber. There are holes at the bottom for the water to drain out and for the sound from the speaker to come through.

You can download the 3d printing files here: https://makerworld.com/en/models/572173

First, you'll need to install the lightsaber sound effects onto the greeting card module. Simply connect the module to your PC and transfer the sound effects, ensuring you delete the default music, leaving only your chosen lightsaber sound effect.

I created two versions of the lightsaber sound: one is 15 seconds long, and the other is 30 seconds long. You can choose the version you prefer.

Always test the sound effect and the light sensor before continuing

The wiring involves extending all connections from the greeting card sound module:

• The speaker wiring extends to the bottom cap of the lightsaber casing.
• The battery is connected to a 3xAAA battery holder.
• The light sensor, which triggers the lightsaber sound effect, is also extended to the bottom cap.
• A limit switch extends from the top of the bottle down to the cap for the LED ring.

You'll need to paint the lightsaber casing before starting anything else.. here im using only 2 color.. black and silver..

i recommend using multicolor 3d printing for the lightsaber as it is a hassle to mask and spray paint the lightsaber..

Once you finished coloring.. you'll need to install the M3 brass threaded insert onto the lightsaber casing..

For the bottom cap, you'll need to run three pairs of wires to the electronic box in the middle:

1. Speaker wires
2. Light sensor wires
3. LED ring wires

Solder all the wires to their respective hardware and run them through the channel on the side.

I glued the speaker to the bottom of the cap and the LED ring to the cap filter. The light sensor is glued next to the LED ring, facing upward.

Finally, you can add the aluminum rod and secure it to the body of the lightsaber using an M3 flathead screw.

For the main body, start by installing the limit switch at the top. The limit switch will trigger the LED ring to turn on, so wire the switch on COM and NC. This configuration ensures that when the switch is pushed, the power is turned off, and when the switch is released, the power is turned on.

Run the wires from the limit switch to the electronic box in the middle. Next, install the hinge for the cap, which will hold the limit switch in place. If needed, dab a little glue to secure the hinge and prevent it from sinking over time.

Now, solder all the wires to their respective parts on the greeting card module. I recommend screwing the module in place first to make the soldering process easier.

Remember, the positive wire from the limit switch goes to the battery, and another wire goes to the LED ring. The negative wire runs from the LED ring to the battery pack. Therefore, the 3xAAA battery pack will have two sets of wires: one powering the LED ring and the other powering the greeting card module.

Once finished, close the electronics box and screw the case shut.

Finally, test all the connections and sound effects to ensure everything works correctly.

First, let's set up the locking mechanism. You will need a 2mm diameter x 25mm steel dowel pin and a 12mm x 7mm diameter spring. I purchased mine from the Bambulab store (affiliate link).

Start by inserting the dowel into the locking trigger and then into the hole on top. Ensure the latch is facing inward towards the bottle and the spring hole is facing outward. When you insert it, there will be a snap that locks the dowel into place, preventing the latch trigger from exiting the hole.

Next, install the spring. It should rest in the circular hole on both sides of the latch trigger and the hole at the top of the main body.

Insert the button into the side hole at the top of the main body. This button will release the lock that catches the latch.

For the top cap installation, screw the top hinge to the top cap of the lightsaber and make sure to insert the D-ring as well. Once done, you can cap the top and insert the 6mm aluminum rod.

Finally, attach the clear bottle cap to the top cap of the lightsaber. It should fit tightly into the top cap hole. If it's loose, apply a little glue to keep it in place. Cut the rubber insert on the clear bottle cap in half to reduce friction, which ensures the lightsaber water bottle closes properly. This small rubber piece also acts as a spring, slightly lifting the top cap.

Now, your lightsaber water bottle is complete.

I had a lot of fun making this lightsaber water bottle, and I'm excited to create more designs with different colors. I'll be sharing the Anakin lightsaber version on my MakerWorld page soon. The wiring and assembly will be the same. Don't forget to like and follow me for more designs!

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