As a huge fan of both Star Wars and Arcane, I designed a custom lightsaber inspired by the designs of the Hextech weapons from Arcane. I designed it from scratch to be fully printable on any single-color FDM printer.

Print Instructions:

• This saber is meant to be printed as separate pieces and then assembled all together. (See note in Assembly section)

• To have good strength and weight, I recommend printing the main body pieces with 5 walls and a 50% gyroid infill, of course, that is up to you, but that helps avoid a broken piece after they are all glued together, nothing is worse than an already assembled saber breaking and then having to start the whole project over.

• For the gems, gold accent pieces, and the belt clip especially, print with 100% infill for strength.

• No supports should be needed, I designed everything to be printable on its own.

• I recommend you print on a smooth or mostly smooth build plate, as texture can add gaps to the pieces that results in the final print not looking as clean.

• You may have to reorient some pieces from the default STL orientation, I find that using the “Auto Orient Objects on Current Build Plate” option in OrcaSlicer works perfectly for everything except for the Left and Right gems, Print the gems with the chamfered side facing up! The Auto-Orient option does not work in OrcaSlicer for these pieces.

• Tolerances are tested and designed for a 0.12mm layer height on a 0.4mm nozzle, you will have to have your z offset dialed in for the gold accent pieces in particular, as elephants foot can make fitting them into the hilt a challenge.

• The intended color to use is included with the filename, I used 30% wood filament for the wooden elements of the grip, and it turned out really well, with a bit of added texture that really made the grip look natural, I highly recommend it. I included a list of links to the filaments I used at the bottom of the description.

• I used glow-in the dark PLA for the gems. Beware, this type of filament can be particularly abrasive on brass nozzles, so be careful when printing with it, and use a hardened nozzle if you can. If you do not have one, however, since these gems are so small, it won't be the end of the world.

• The connector piece is not visible, and can be printed with whatever filament your heart desires.

Assembly:

• Important Note: I find that it is always a good idea to test and make sure everything fits together before using any glue, so I highly recommend waiting until everything is printed before starting the final assembly process.

• Main Body Pieces: This print is designed to use superglue to attach the main body pieces together, all the connection pieces in the center, and just a little glue around the edges and on top of each connection point should work great and prevent any glue from oozing out the sides of the print.

• Gems: Just a dab of superglue on the back of each gem should hold things in place. The large gem should be inserted before the front gold accent piece.

• Gold Accent Pieces: These should not need any glue to stay in place, though a tiny dab on the back can help. They are designed to slid into the holes at the bottom of the hilt, then the gold accent top piece can be added.

• Keep in mind, the belt clip is designed for aesthetics, and while it can hold up the saber in a pinch, it is not reliable enough to be used for actually holding the weapon on a belt when moving around, so I do not recommend relying on it.

Filaments Used:

• Wooden PLA: OVV3D Wood - Cherry
• Gold PLA: Polymaker Silk PLA - Shiny Silk Gold
• Silver PLA: Polymaker Silk PLA - Shiny Silk Chrome
• Copper PLA: Amazon Basics Silk PLA - Copper
• Leather Brown PLA: DURAMIC 3D PLA+ - Brown
• Glow In The Dark Blue PLA: TECBEARS Glow in The Dark PLA - Blue