u/Proud_Case_3339

Starting about 2 years ago, I set a goal for myself to create a better 3d printed lightsaber design. I wanted my design to be completely 3d printable, glueless, sturdy, and not require the use of AMS or painting to make it look good. All of the other ways of constructing lightsaber hilts did not satisfy me. Instead, I created a hilt that's built around an internal bar acting as a frame to align each of the pieces together. The ends are then threaded and act as a tensioner to help keep everything feeling tight and sturdy. Plus, it is very compact! I can get the diameter down to 30 mm and still have reliable buttons, covertec wheels, and more.

I have thoroughly tested this method to be reliable across several different hilt designs and sizes, and have worn, played with, dropped, disassembled, reassembled, and generally fidgeted to my heart's content.

This hilt (Darth Maul's broken lightsaber) is my first to use my working buttons that utilize a fully printed spring. It also has spinning rings and rotating knobs. The covertec wheel is even fully functional and fairly beefy. Even being very sturdy, nothing needs supports either.

I try not to rush my designs, and I hope that I will be able to further improve upon this method continually in the future. I would love to hear any feedback or suggestions in ways I can better my design, or a certain hilt that you would like me to make!

Here is the link as well: Darth Maul Broken Lightsaber - Free 3D Print Model - MakerWorld

Starting about 2 years ago, I set a goal for myself to create a better 3d printed lightsaber design. I wanted my design to be completely 3d printable, glueless, sturdy, and not require the use of AMS or painting to make it look good. All of the other ways of constructing lightsaber hilts did not satisfy me. Instead, I created a hilt that's built around an internal bar acting as a frame to align each of the pieces together. The ends are then threaded and act as a tensioner to help keep everything feeling tight and sturdy. Plus, it is very compact! I can get the diameter down to 30 mm and still have reliable buttons, covertec wheels, and more.

I have thoroughly tested this method to be reliable across several different hilt designs and sizes, and have worn, played with, dropped, disassembled, reassembled, and generally fidgeted to my heart's content.

This hilt (Darth Maul's broken lightsaber) is my first to use my working buttons that utilize a fully printed spring. It also has spinning rings and rotating knobs. The covertec wheel is even fully functional and fairly beefy. Even being very sturdy, nothing needs supports either.

I try not to rush my designs, and I hope that I will be able to further improve upon this method continually in the future. I would love to hear any feedback or suggestions in ways I can better my design, or a certain hilt that you would like me to make!