V3.2
V3.2
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The main evolution between V3.1 and V3.2 was the evolution of the electronics package, and the redesign of the hilt as the result of the redesigned electronics package.
The main evolution between V3.1 and V3.2 was the evolution of the electronics package, and the redesign of the hilt as the result of the redesigned electronics package.
The evolved electronics package was designed as a clamshell in order to function as both shelf and shell. This redesign allocated more space to wiring, but lengthened the overall package. This required lengthening the hilt to accommodate.
The evolved electronics package was designed as a clamshell in order to function as both shelf and shell. This redesign allocated more space to wiring, but lengthened the overall package. This required lengthening the hilt to accommodate.
V3.2 also included a redesign of the entire blade. The custom polycarbonate tube, blade tip, and Delrin diffusion tube were all replaced with a commercially available lightsaber blade tube from Ultrasaber. This included a pre-installed diffusion film and blade tip. This both simplified manufacturing and improved the quality of the final product.
V3.2 also included a redesign of the entire blade. The custom polycarbonate tube, blade tip, and Delrin diffusion tube were all replaced with a commercially available lightsaber blade tube from Ultrasaber. This included a pre-installed diffusion film and blade tip. This both simplified manufacturing and improved the quality of the final product.
The interior of the blade was also redesigned. While previous iterations had the LED strips loosely placed inside, this iteration secured the LED strips to either side of corrugated plastic support. This support flares at the end closest to the hilt to provide clearance for the wires.
The interior of the blade was also redesigned. While previous iterations had the LED strips loosely placed inside, this iteration secured the LED strips to either side of corrugated plastic support. This support flares at the end closest to the hilt to provide clearance for the wires.
The last design change on the blade was to the structural connection between the blade and the hilt. Like all previous iterations, the blade is secured to the hilt by a metal component that is connected to the hilt mechanically by a screw. This iteration differs from previous ones in how this metal component is connected to the blade itself. Previous designs had this component attached to the blade with epoxy. However, this conflicts with my design methodology for hobby projects like this. On projects like this that require a lot of iteration and tinkering, my design methodology is to avoid permanent connections. For this reason, the blade support was redesigned to clamp onto the blade.
The last design change on the blade was to the structural connection between the blade and the hilt. Like all previous iterations, the blade is secured to the hilt by a metal component that is connected to the hilt mechanically by a screw. This iteration differs from previous ones in how this metal component is connected to the blade itself. Previous designs had this component attached to the blade with epoxy. However, this conflicts with my design methodology for hobby projects like this. On projects like this that require a lot of iteration and tinkering, my design methodology is to avoid permanent connections. For this reason, the blade support was redesigned to clamp onto the blade.
Additionally, this iteration implemented an electrical interface between the blade and hilt. These 3D printed components exist on the either side of the connection, and host a key and tapered guide, allowing for a minor angular misalignment of blade and hilt to be corrected before the male and female pins come into contact. This ensures a proper connection and prevents any damage to the male pins.
Additionally, this iteration implemented an electrical interface between the blade and hilt. These 3D printed components exist on the either side of the connection, and host a key and tapered guide, allowing for a minor angular misalignment of blade and hilt to be corrected before the male and female pins come into contact. This ensures a proper connection and prevents any damage to the male pins.
When redesigning the hilt, the opportunity was taken to again make aesthetic changes, taking inspiration from the lightsabers of notable Star Wars characters. The hilt design was 3D printed to provide fit checks with the electronics and allow for fully integrated testing before manufacturing the final metal body.
When redesigning the hilt, the opportunity was taken to again make aesthetic changes, taking inspiration from the lightsabers of notable Star Wars characters. The hilt design was 3D printed to provide fit checks with the electronics and allow for fully integrated testing before manufacturing the final metal body.
Fit checks with the final electronics revealed that the monolithic central body presented challenges for assembly and kyber crystal installation. This lead to a redesign of central hilt component to incorporate a door, allowing the wiring and kyber crystal to be accessed without disassembling the entire hilt. However, the initial design would have presented significant challenges for manufacturing. This triggered a complete design review of the hilt and subsequent design optimization for manufacturing. This redesign, among other improvements, were the included in the V3.3 iteration.
Fit checks with the final electronics revealed that the monolithic central body presented challenges for assembly and kyber crystal installation. This lead to a redesign of central hilt component to incorporate a door, allowing the wiring and kyber crystal to be accessed without disassembling the entire hilt. However, the initial design would have presented significant challenges for manufacturing. This triggered a complete design review of the hilt and subsequent design optimization for manufacturing. This redesign, among other improvements, were the included in the V3.3 iteration.
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