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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Christopher Bouzy
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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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thread 7/42
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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thread 13/42
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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Christopher Bouzy
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thread 16/42
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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thread 17/42
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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Christopher Bouzy
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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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thread 20/42
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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thread 23/42
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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Christopher Bouzy
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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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Christopher Bouzy
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thread 28/42
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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Christopher Bouzy
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The bottom and middle sections are completed.
08:50 PM - May 03, 2023
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Christopher Bouzy
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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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Christopher Bouzy
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Lots of wires...
11:36 AM - May 04, 2023
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Christopher Bouzy
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Almost ready to test.
11:38 AM - May 04, 2023
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Christopher Bouzy
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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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Christopher Bouzy
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Accent lights installed.
11:43 AM - May 04, 2023
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Christopher Bouzy
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I finished polishing the hilt.
11:44 AM - May 04, 2023
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Christopher Bouzy
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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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Christopher Bouzy
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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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Gin Perdide
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That is just gorgeous Chris. How many hours did it take to make? What did your little one think of it? Thank you so much for sharing all this with us. 😍
In response to Christopher Bouzy.
06:17 PM - May 04, 2023
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Christopher Bouzy
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In response to Gin Perdide.
It took months, but I wasn't working on it full-time. Liam LOVED it!
01:39 PM - May 05, 2023
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