With all the design work done for my Custom Cutaway Lightsaber, it's time to 3D print everything on the Form 2 SLA printer. We were lucky enough to get a pre-production Form 2 from FormLabs and had been printing a ton of projects before the official release. We were very pleased with all the prints as Formlabs had upgraded all of the items (and then some) on my wishlist from my time with the Form 1+. The Form 2 had been living up to my expectations but I designed some of the lightsaber parts to torture test it further.
While the Form 2 was more than capable of printing out an entire half of the saber in one piece, I broke it up into many parts for a few reasons. First, I wanted to show off various resins and designed the saber to make use of the black, grey, clear and flexible materials, most of which had just had formulation upgrades. Second, I wanted to see what the tolerances and fit quality were like for assemblies. Third, as we have talked about before, prints tend to look better when all the parts aren't globbed together but instead printed as individual pieces. Plus, the quality of parts can sometimes be affected by orientation and printing everything as one piece is not always optimal.
Once modeling was finished, the next step was to export all the parts as STL files - generally the standard for 3D printing. The grips and pommel were exported as a whole piece and then cut in half using Netfabb - this was a case of using the right tool for the job. Netfabb (recently acquired by Autodesk) is also my goto program for mesh repair which is a vital part of 3D printing. Any holes, flipped polygon faces or other irregularities can cause a print to fail. Formlabs PreForm software has Netfabb repair functionality built in and will warn you and offer to fix possible issues upon model import.