Making a 3D-Printed Sith Lightsaber Kit!

We’re thrilled to unveil a new 3D printed project from Sean Charlesworth! Sean was inspired to design and print his own Star Wars-inspired lightsaber, but with his own twist: this Sith model is a cutaway design that shows the internal construction of the hilt. Sean discusses how he came up with this design and how he used the Formlabs Form 2 printer fabricate it. Plus, the design files are free for anyone to download!

Comments (21)

21 thoughts on “Making a 3D-Printed Sith Lightsaber Kit!

  1. Good God, Sean. Your work is so meticulous. Such tiny little details, and so well polished… Truly gorgeous stuff.

    Only the top “fins” made me a little concerned because it looks like they could break off rather easily. I’d make them a bit thicker at the base, like a long pyramid or however that form is called.

    Still, super duper neat.

  2. How long have you spent working on this ? I have just about finished my own 3d printed respberry pi handheld device and I have worked on it for almost two months. It is my first big 3d printed project on a new flashforge dreamer so a lot of time was working out the best way to print parts, but it is simple compared to this.

  3. I think I work slow, but I was really proud of myself for finishing this in about a month and a half. The Ghost Trap took me about 3 months, the Ocotopod took 8 months. You’ll get faster the more you do!

  4. Nice! Also, designing things that must fit other parts and together can be much harder and time-consuming than prints that are more ‘sculptural’ – not that insanely detailed sculpts aren’t awesome AND time consuming.

  5. awesome work. Had a 3d printer for about 5 years now and after seeing this I think its time for an upgrade.

    How much resin was used on this project.

  6. Excellent job, designing something cool is one thing but designing something that’s also functional takes a good bit of time and know how

  7. Anyone interested in how the original Star Wars lightsaber came to be should check out the prop maker Roger Christian’s new book ‘Cinema Alchemist: Designing Star Wars and Alien’. A fascinating read!

  8. Awesome!!! I printed the first one. I will try this one some day

    ( I tried to upload a picture, but there was an error…

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