V1.0 Lightsaber

The first iteration of my lightsaber, denoted as V1.0, was a simple first attempt at a lightsaber capable of of a duel. It was also my first project using a manual mill and lathe. This iteration lacked any electronics, with the only designs goal being structural integrity, and replicating the dimensions and appearance of a lightsaber.

The design has two parts: a hilt and a blade. The hilt is constructed from a 3D printed plastic shell mounted around a machined aluminum core. This design allowed the aluminum core to take any loads or shocks, and for the plastic shell to provide the aesthetic features and geometries without the need for complex machining operations.

The blade consists of four segments, held together by short lengths of threaded rod. Each of the four is machines from Delrin. Three of the segments are simple straight segments, while the fourth segment is tapered to form the tip of the blade. Unfortunately, the combination of Delrin and steel rod resulted in a fairly heavy blade, resulting in a center of gravity far too far forward for the combined lightsaber to be swung around comfortably or safely.

This iteration was far from a satisfactory final product, but was a good place to start. Most importantly, the poor placement of the center of gravity taught me how important it would be to get right on future iterations.