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Custom Lightsaber Assembly (No glue, No Supports) 3D Printer File Image 1
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Custom Lightsaber Assembly (No glue, No Supports)

Orion3D Studios avatarOrion3D Studios

March 28, 2025

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DescriptionCommentsTags

Description

Introduction

This is a no-glue-required build. The parts are threaded to make for easy assembly. Perfect as a gift or to make a fine addition to your collection.

Parts list
1x Pommel
1x Hexacore Diatium Power Cells
3x Palladium Vortex Rings
1x Power Casing
1x Leather Wrap
1x Midgrip
1x Cycling Energy Fields
1x Kyber Crystal
1x Magnetic Stabilization Ring
1x Emitter
1x Emitter Shroud
1x Activation Input
1x Giftbox (optional) fits a prusament box
1x Doubleblade adapter (optional) - Only part that requires supports.

Assembly
Important note: Do not screw too tightly or risk popping the screw off the part.
Note: nothing is needed other than the printed parts.

  1. Screw the Pommel and the Hexacore Diatium Power Cells together.
  2. Place the three Palladium Vortex Rings on the shaft of the Hexacore Diatium Power Cells.
  3. Screw the Power Casing to the Pommel
  4. Slide the Leather Wrap onto the Power Casing.
  5. Screw the Midgrip onto the Power Casing.
  6. Push the Kyber Crystal into the Cycling Energy Field. 
  7. Friction fit the Magnetic Stabilization Ring onto the Cycling Energy Field.
  8. Screw the Cycling Energy Field into the Midgrip.
  9. Place the Emitter loosely into the Emitter Shroud.
  10. Screw the Emitter onto the Magnetic Stabilization Ring.
  11. Screw the Shroud onto the Magnetic Stabilization Ring.
  12. Press the Activation Input onto the Midgrip.

Now you are ready to become a Jedi Master.

UPDATE 12/24/23 
Power Cycling Fields - by increasing the prongs for additional stability.
Magnetic Stabilization Ring - Modified to accommodate the PCF change and reduced the tolerance between the two parts for a better fit.
Kyber Crystal - slightly down for better tolerance with the Magnetic Stabilization Ring.

UPDATE 12/11/23 - Adjusted the Box Inserts to accommodate the 12/9/23 changes.

UPDATE 12/9/23 - I took in feedback and redesigned parts to make every part supportless (except the optional doubleblade adapter). Test-printed and assembled the parts for QA. See details below.
Pommel - Removed the dubious ring that was to act as a stop for the wrap
Power Cells - No change
Vortex Rings - Reduced height to create room for modified midgrip base
Power Casing - No change
Leather Wrap - Made it thicker to better align with the Midgrip and for cleaner printing
Midgrip - Modified the base to eliminate a floating piece and for strong print stability
Activation Input - Changed the insert pattern.
Cycling Energy Fields - Adjusted model to make bridging possible and added a top
Kyber Crystal - No change
Magnetic Stabilization Ring - Adjusted print base and changed screw orientation
Emitter - Changed screw orientation
Shroud - No change 
Doubleblade adapter - Removed the dubious ring. 


This is part of a friendly competition with my buddy @TheTrueMzungu_65757, so please give his saber a look as well!

 

License:

Creative Commons — Attribution

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