V3.3
V3.3
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After completion of the V3.2 prototype with 3D printed stand-ins for the metal components, it was used to evaluate the overall design and discover any issues that may require further iteration. These minor changes were all rolled into this V3.3 iteration. These changes included optimizing the design for manufacturing, one small change to the electronics to improve power usage, and a handful of additions for purely aesthetic purposes.
After completion of the V3.2 prototype with 3D printed stand-ins for the metal components, it was used to evaluate the overall design and discover any issues that may require further iteration. These minor changes were all rolled into this V3.3 iteration. These changes included optimizing the design for manufacturing, one small change to the electronics to improve power usage, and a handful of additions for purely aesthetic purposes.
The most drastic evolution between V3.2 and V3.3 is the redesign of hilt components to optimize manufacturing. The most visible changes are to the hilt's central component, the door, and the pommel. The complex geometry on V3.2s central component and door were completely eliminated. The purpose of this geometry was to securely mount the door using the same screws that hold the hilt itself together. The need for this complex geometry was removed by changing how the door is secured.
The most drastic evolution between V3.2 and V3.3 is the redesign of hilt components to optimize manufacturing. The most visible changes are to the hilt's central component, the door, and the pommel. The complex geometry on V3.2s central component and door were completely eliminated. The purpose of this geometry was to securely mount the door using the same screws that hold the hilt itself together. The need for this complex geometry was removed by changing how the door is secured.
The design change to the pommel included splitting the pommel into two parts in order to remove the need for CNC machining. While these components will likely still be manufactured on CNC machines, I chose to design these components to able to be machined manually. This ensures the parts can still be manufactured without access to CNC machines.
The design change to the pommel included splitting the pommel into two parts in order to remove the need for CNC machining. While these components will likely still be manufactured on CNC machines, I chose to design these components to able to be machined manually. This ensures the parts can still be manufactured without access to CNC machines.
One of the more aesthetically driven changes was the removal of 3D printed caps to cover the screws. While the screws are necessary to hold the hilt together, they interrupt the appearance of the lightsaber. However, the idea of the caps would not work as well as initially thought. While they would hide the screw, the transition between body and cap would not be perfect and likely would be obvious. For this reason, they were replaced with 3D printed parts that not only cover the screws, but add to overall appearance in order to distract from what they are hiding.
One of the more aesthetically driven changes was the removal of 3D printed caps to cover the screws. While the screws are necessary to hold the hilt together, they interrupt the appearance of the lightsaber. However, the idea of the caps would not work as well as initially thought. While they would hide the screw, the transition between body and cap would not be perfect and likely would be obvious. For this reason, they were replaced with 3D printed parts that not only cover the screws, but add to overall appearance in order to distract from what they are hiding.
Like V3.2, components of the body and exterior were 3D printed in order to perform fit checks and evaluate integrated assembly. Part of this evaluation was a test of the battery life at idle. This found that even at rest, the battery could not last a full 24 hours. Given that having to replace the battery every time would be a huge inconvenience, a simple cutoff was added underneath the door. A small wire was connected to the voltage regulator that, when connected to ground, shuts off all power to the electronics. While it is still a slight inconvenience o remove the door to turn the power on, it is better than disassembling the hilt to replace the battery.
Like V3.2, components of the body and exterior were 3D printed in order to perform fit checks and evaluate integrated assembly. Part of this evaluation was a test of the battery life at idle. This found that even at rest, the battery could not last a full 24 hours. Given that having to replace the battery every time would be a huge inconvenience, a simple cutoff was added underneath the door. A small wire was connected to the voltage regulator that, when connected to ground, shuts off all power to the electronics. While it is still a slight inconvenience o remove the door to turn the power on, it is better than disassembling the hilt to replace the battery.
Lastly, I compared my V3.3 prototype to a commercially available lightsaber from Disney. In the image above, Disney's lightsaber is on the left, and my V3.3 is on the right. While the does have a few advantages over the Disney lightsaber, there are some nice features on Disney's that V3.3 lacks, such as a better blade-to-hilt interface, better battery life, and better detection of the kyber crystal. I plan to add these features to my V4 lightsaber design.
Lastly, I compared my V3.3 prototype to a commercially available lightsaber from Disney. In the image above, Disney's lightsaber is on the left, and my V3.3 is on the right. While the does have a few advantages over the Disney lightsaber, there are some nice features on Disney's that V3.3 lacks, such as a better blade-to-hilt interface, better battery life, and better detection of the kyber crystal. I plan to add these features to my V4 lightsaber design.
The V3.3 lightsaber is still a work in progress, as the metal components have not yet been manufactured.
The V3.3 lightsaber is still a work in progress, as the metal components have not yet been manufactured.
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