Welcome to Part 2 of our custom lightsaber mounts Practical Print series! If you haven't gotten a chance to checkout the Design step, be sure to catch up there first! Don't worry, we'll wait.
Here's a little recap of the project specs and requirements:
Two custom top and bottom lightsaber mounts
Attachment at the hilt only
An opening at the bottom for a ribbon wire to pass through
Minimal and unobtrusive in design
Darth Vader lightsaber
The two notches on the back of the Darth Vader hilt are different in both diameter and depth. In order for this to work, we needed the canal size to fit the larger dimensions of the two. We also wanted the canal to taper to a smaller width so that the notches stayed secure.
A very useful command to accomplish this in Rhinoceros 3D was the ‘Sweep2’ command which allowed us to create a surface edge between two curves. That was the main focus of this piece, so the rest of the model was just going to be the base.
For the bottom mount, we just needed the outer diameter of the hilt, as well as the diameter of the battery compartment to determine the size of the hole. We designed this mount such that the hilt could sit snug inside the circular base and the ribbon cable could come out the bottom easily. For the back of the mount that rests against the wall, we needed it to be thick enough so that we could adhere it to the wall, but slim enough that it wouldn’t be noticeable once mounted. We shaped the “spine” of it based on where the bumpers on the hilt were located.
Anakin Skywalker lightsaber
We modeled the hinge of this mount after a standard door hinge. We altered the geometry of this, however, so that you wouldn’t need a separate pin piece to hold the hinge together through the center.
To do this, we had one half modeled with the top and bottom segment of the hinge. Then the second half contained the center piece, with two smaller “pins” coming out of the top and the bottom.
For this to work, we needed to get the offsets and tolerances just right so that there’s enough room for the pieces to move, but they’re held together tightly enough that they won’t come apart. We wanted to make this as a single print with moving parts so we needed to make sure the mobile parts of the print had enough gaps between them that we can easily move them after they’re printed.
The bottom mount was very similar in design to the bottom mount of the Darth Vader lightsaber, but the diameter was smaller and the backside was modeled differently since the bumpers are different as well.
And with that, we have all of the pieces we need to get started on the prototyping process! Come back next week to see how we did, what adjustments we need to make, and how the final pieces turned out!