Christopher Bouzy
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thread 1/42
This thread is dedicated to my last lightsaber build. I will show the entire process from beginning to end. I hope you guys enjoy it!

I used pre-machined parts for the hilt, but I added custom accent elements to make it unique.
07:24 PM - May 03, 2023
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Christopher Bouzy
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thread 2/42
This was the beginning stage of the crystal chamber. I designed it in Shapr3D and then 3D printed it using specialty PLA. This lightsaber build allows me to open it up to reveal the internal components.
07:25 PM - May 03, 2023
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Christopher Bouzy
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thread 3/42
I soldered JST-PH 2.0 connectors to the soundboard to ensure the electronics and LED strips worked correctly. I used the Golden Harvest v3 soundboard; it is the main component of the lightsaber.
07:25 PM - May 03, 2023
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Christopher Bouzy
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Everything worked as expected.
07:28 PM - May 03, 2023
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I decided to go with a slightly different hilt design.
07:31 PM - May 03, 2023
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Christopher Bouzy
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More of the crystal chamber design.
07:32 PM - May 03, 2023
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Christopher Bouzy
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I made changes to the crystal chamber, and I 3D printed the parts with a cheap filament to see how everything fit.
07:36 PM - May 03, 2023
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Christopher Bouzy
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I started adding brass accent parts to the lightsaber.
07:39 PM - May 03, 2023
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Christopher Bouzy
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I ended up making changes to the hilt and pommel. I also added more brass accent pieces.
07:42 PM - May 03, 2023
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Christopher Bouzy
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thread 10/42
I made a synthetic Kyber crystal. First, I made a mold using a genuine crystal and a silicone mold kit. Then I filled the mold with clear resin and added a Neopixel at the base of the Kyber crystal. Now the Kyber crystal will light up when the lightsaber is on.
07:44 PM - May 03, 2023
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Christopher Bouzy
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Here is the crystal in action.
07:48 PM - May 03, 2023
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Christopher Bouzy
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This is the Kyber crystal seated in the prototype crystal chamber. The crystal chamber was 3D printed with a cheap matte filament for fit...etc. When all of the parts are designed and fit as expected, I will use metal-infused filaments for the internal chassis.
07:51 PM - May 03, 2023
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Christopher Bouzy
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This is how the Kyber crystal will look inside of the lightsaber hilt.
07:52 PM - May 03, 2023
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Christopher Bouzy
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I finished designing the first half of the lightsaber chassis. Everything fits perfectly inside of the hilt and works as expected. Now I can 3D print the top half parts in the more expensive metal-infused filament and start working on the bottom half of the chassis.
07:57 PM - May 03, 2023
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Christopher Bouzy
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thread 15/42
I printed the parts with filaments filled with metal. This particular filament is filled with iron, and it's actually magnetic. Once it is sanded, it can oxidize and rust. I used filaments filled with bronze and copper.
08:00 PM - May 03, 2023
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The first photo is a standard PLA part, and the second photo is an iron-filled PLA part. Part A is 16 grams and part B is 23 grams.
08:03 PM - May 03, 2023
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Christopher Bouzy
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The finished design of the chassis. Now it is time to print the rest of the parts and put it all together.
08:22 PM - May 03, 2023
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The internal 3D parts are ready for post-processing. The metal-filled 3D printed parts still look like plastic until they are sanded...etc. But when everything is done, they will look like metal.
08:28 PM - May 03, 2023
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Christopher Bouzy
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thread 19/42
It's starting to look metallic, but a lot more post-processing is required.
08:28 PM - May 03, 2023
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Christopher Bouzy
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Since I used metal-filled PLA, the parts can oxidize and rust. I used a 50/50 solution of vinegar and hydrogen peroxide mixture to accelerate the process.
08:31 PM - May 03, 2023
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Christopher Bouzy
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It took less than a day for the parts to look old and rusted.
08:32 PM - May 03, 2023
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I sanded the parts again, removing some of the rust...etc. Nice subtle patina.
08:34 PM - May 03, 2023
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Christopher Bouzy
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I used a pure brass wire brush to expose the metal in the filament, but some of the brass transferred to the part for a cool effect. I then used a tiny amount of gold leaf glue and metallic powders to make the part look realistic. A tiny amount of the powder goes a long way.
08:37 PM - May 03, 2023
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Close-up view.
08:37 PM - May 03, 2023
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First coat of clear coat.

Note: I use double-sided tape to hold the part while spraying on the clear coat.
08:38 PM - May 03, 2023
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Before and after.
08:39 PM - May 03, 2023
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It is time to start assembling the inner components of the lightsaber.
08:41 PM - May 03, 2023
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Some parts were glued and clamped. I used Gorilla Glue because it doesn't dry quickly and is easy to clean up. The problem with Gorilla Glue is it expands, so only a little is needed.
08:45 PM - May 03, 2023
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Christopher Bouzy
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thread 29/42
I used 3D-printed parts combined with genuine metal parts for a more realistic appearance.
08:49 PM - May 03, 2023
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The bottom and middle sections are completed.
08:50 PM - May 03, 2023
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Assembly of the internal chassis is completed, and now it is time to install the soundboard and wire up everything.
11:33 AM - May 04, 2023
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Christopher Bouzy
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The emitter is soldered and ready to be installed into the internal chassis.
11:35 AM - May 04, 2023
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Lots of wires...
11:36 AM - May 04, 2023
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Almost ready to test.
11:38 AM - May 04, 2023
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The first test went well. Now it is time to add accent lights.
11:40 AM - May 04, 2023
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A quick demo.
11:42 AM - May 04, 2023
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Accent lights installed.
11:43 AM - May 04, 2023
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I finished polishing the hilt.
11:44 AM - May 04, 2023
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The steps to putting the internal chassis into the hilt.
11:46 AM - May 04, 2023
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Lightsaber on display.
11:47 AM - May 04, 2023
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You can activate the lightsaber with gesture controls. Here I used a wrist twist.
11:49 AM - May 04, 2023
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Christopher Bouzy
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Another quick demo.
11:51 AM - May 04, 2023
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Blaine Fergerstrom
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In response to Christopher Bouzy.
That is quite insane! Beautiful work, man!
05:52 PM - Jul 02, 2023
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Acey Deecey 🚀🚀
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In response to Christopher Bouzy.
I am so jealous. I bought a purple lightsaber many moons ago at Comic Con. It was pricy but super well made. The problem was if I was wanted the sound chip it was like an extra $50 and I just didn't have the money. So my Mace Windu lighsaber has no sound. 😔😔
11:24 AM - May 05, 2023
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Trish
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In response to Christopher Bouzy.
Sweet! 🤓
09:24 PM - May 04, 2023
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K Ray
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In response to Christopher Bouzy.
Is it battle-ready?
08:01 PM - May 04, 2023
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