Custom Lightsaber
Custom Lightsaber
As a lifelong Star Wars fan, one of my personal goals has always been to have a lightsaber. While I could easily buy a one online, I personally would get more enjoyment out of designing and building my own from scratch. This project as a whole has required me to execute: mechanical design, electrical design, design for manufacturing, wiring/soldering, programming, machining, 3D printing, troubleshooting, and constantly looking for possible improvements. For this reason, the design has gone through numerous iterations. You can read about the history and design of each iteration below. This project is one of my favorites. Not only does it fulfil a lifelong goal, but it is also a complex, multi-disciplinary project that has taught me a lot, and encompasses many of my skills as an engineer.
As a lifelong Star Wars fan, one of my personal goals has always been to have a lightsaber. While I could easily buy a one online, I personally would get more enjoyment out of designing and building my own from scratch. This project as a whole has required me to execute: mechanical design, electrical design, design for manufacturing, wiring/soldering, programming, machining, 3D printing, troubleshooting, and constantly looking for possible improvements. For this reason, the design has gone through numerous iterations. You can read about the history and design of each iteration below. This project is one of my favorites. Not only does it fulfil a lifelong goal, but it is also a complex, multi-disciplinary project that has taught me a lot, and encompasses many of my skills as an engineer.
Version 1
Version 1
It would be unreasonable to expect to get it right on the first try, but this project had to start somewhere. My first attempts at building a lightsaber, denoted as Version 1 or V1, were both very crude iterations that greatly influenced the design of later iterations. There was more to be learned from what these iterations got wrong than from what they got right.
It would be unreasonable to expect to get it right on the first try, but this project had to start somewhere. My first attempts at building a lightsaber, denoted as Version 1 or V1, were both very crude iterations that greatly influenced the design of later iterations. There was more to be learned from what these iterations got wrong than from what they got right.
V1.0 was my first attempt at building anything resembling a lightsaber, and succeeded in replicating the dimensions and general aesthetics of a lightsaber. However, this iteration lacked any electronics and had a center of gravity far too far forward to be usable.
V1.0 was my first attempt at building anything resembling a lightsaber, and succeeded in replicating the dimensions and general aesthetics of a lightsaber. However, this iteration lacked any electronics and had a center of gravity far too far forward to be usable.
V1.1 was the first attempt at implementing electronics and an illuminated blade. However, building it around the V1.0 architecture presented too many design constraints to achieve a satisfactory final product.
V1.1 was the first attempt at implementing electronics and an illuminated blade. However, building it around the V1.0 architecture presented too many design constraints to achieve a satisfactory final product.
The most valuable lesson from both V1.0 and V1.1 was their shortcomings, as they underscored the important of what would become the core features of future iterations.
The most valuable lesson from both V1.0 and V1.1 was their shortcomings, as they underscored the important of what would become the core features of future iterations.
Version 2
Version 2
V2 was the first major redesign of my lightsaber. This design achieved a proper center of gravity and an illuminated blade. However, this design lacked sounds or any or other features of commercially available lightsabers. After calculating what this design would cost in parts and materials, I decided it was not worth the limited capability.
V2 was the first major redesign of my lightsaber. This design achieved a proper center of gravity and an illuminated blade. However, this design lacked sounds or any or other features of commercially available lightsabers. After calculating what this design would cost in parts and materials, I decided it was not worth the limited capability.
Version 3
Version 3
V3 was the first iteration to incorporate sounds and motion detection, and an internal color sensor to set the blade color. Additionally, V3 was the first design iteration to design the electronics first, and then the body around it.
V3 was the first iteration to incorporate sounds and motion detection, and an internal color sensor to set the blade color. Additionally, V3 was the first design iteration to design the electronics first, and then the body around it.
V3.2 was also the first generation to use 3D printing for rapid prototyping of the geometry and fit. Below is the first fit check of the V3.2 hilt. Later fit checks with the electronics uncovered difficulty with assembly, ultimately leading to the V3.3 generation.
V3.2 was also the first generation to use 3D printing for rapid prototyping of the geometry and fit. Below is the first fit check of the V3.2 hilt. Later fit checks with the electronics uncovered difficulty with assembly, ultimately leading to the V3.3 generation.
V3.3 is the most advanced iteration I have built so far, and is the only one currently built to a quality comparable to commercially available lightsabers. In the picture to the right is a comparison between a lightsaber sold by Disney (on the left) and my V3.3 iteration (on the right).
V3.3 is the most advanced iteration I have built so far, and is the only one currently built to a quality comparable to commercially available lightsabers. In the picture to the right is a comparison between a lightsaber sold by Disney (on the left) and my V3.3 iteration (on the right).
Version 4
Version 4
V4 is currently in development, and with the goal of improving manufacturability, and implementing other lessons learned from building V3.3. One of these changes is mounting the electronics to a custom PCB to simplify the wiring and soldering needed for assembly. A dedicated page for V4 will be added once the design is closer to completion.
V4 is currently in development, and with the goal of improving manufacturability, and implementing other lessons learned from building V3.3. One of these changes is mounting the electronics to a custom PCB to simplify the wiring and soldering needed for assembly. A dedicated page for V4 will be added once the design is closer to completion.