We've been using the Formlabs Form 2 SLA 3D printer since its release and have loved our experience with it so far. The Form 2 produces high-resolution models using liquid resin cured via laser. Formlabs recently introduced new formulations of most of their resins and various software and firmware updates, which I wanted to put to the test. So when the opportunity came to create a custom project with Formlabs, I wanted to see how far I could push the detail and precision of the Form 2.
Since I've always wanted to make a Star Wars lightsaber and love seeing how things work, I proposed the Cutaway Lightsaber Project. The first decision was choosing what kind of lightsaber to make. The movie sabers have been done many times over, so I decided to design my own--like a true Jedi... or Sith. The lightsabers from the Star Wars prequels tended to be more sleek and refined, but I wanted the chunkier look of the original movies that I grew up with. As most fans know, many of the original props, including the lightsabers, were designed from found objects such as Graflex camera flash handles. Additional details, known as greeblies, were added to complete the prop and make it look appropriately sci-fi. With my background in film & TV repair, I have collected a lot of oddball and cool-looking parts, so I decided to start in the same way.
I used Luke's Return of the Jedi saber replica as a size reference and started cramming my junk parts together until I had a rough lightsaber that I liked. There was a little of everything: optics, camera parts, hard drive spindles, electrical connectors and miscellaneous gears. I knew this wasn't the final form, but there were a lot of features that I liked. I started recreating approximations of these in 3D, adjusting as needed to accommodate size and other features that I wanted. Early on I knew I wanted to include what I refer to as 'Death Star Grate' which many will recognize as the distinctive pattern of cutouts used as windows, lights, grates, etc throughout the Star Wars Universe. Typically it's used in facilities of the Empire, so I figured this was going to be a bad guy's saber. I wanted it to be beefy and look like it could mess you up even when it wasn't ignited--kind of like a D&D mace.