Modular Crossguard Saber Hilt + Threaded Blade (100% Supportless M26x3.0 3D Print)

A complete 1:1 full-scale Modular Crossguard Combat Saber exported directly from the SaberCraft 3D Forge Studio — shared free as a starter build and thread-fit showcase for our interchangeable M26×3.0 modular saber ecosystem!

Every single .STL component in this build is precision-engineered to print upright flat on Z = 0 with Slicer Supports turned completely OFF.

Key Engineering Features

- Zero Slicer Supports Supports = OFF): All external shrouds, collars, grip ribs, and internal cavities use continuous self-supporting 45° chamfers.
- Universal M26×3.0 Screw Threads: Precision truncated metric threads with 0° clocked stops so every hilt section tightens flush and aligned.
- Supportless Crossguard Architecture: Both horizontal M12×3.0 side quillon nozzles and mini-blades print standing upright on the bed and screw cleanly into the emitter's side sockets.
- Hollow Electronics & Weighting Bore: Continuous internal pass-through channel Ø24.4 mm grip chamber / Ø16.6 mm thread pass-through) for LED wiring, chassis rods, or steel core weighting.

Recommended Slicer Settings (FDM)

- Supports: DISABLED / OFF (Important: do NOT enable supports inside the threads!)
- Layer Height: 0.16 mm – 0.20 mm
- Wall Loops / Perimeters: 3 – 4 walls (puts solid material behind every thread tooth)
- Infill: 20% – 25% Gyroid or Cubic
- Bed Adhesion: Standard outer Brim (5–8 mm, Outer Brim Only) recommended for tall narrow parts (blade tubes, choke, and crossguard side nozzles).
- Filament: PLA+, Tough PLA, Silk Metallic PLA, PETG, or ASA. 

Full slicer, filament, and thread tolerance chart: Supportless 3D Printing Guide

Assembly Order

1. Pommel & Grip: Thread the headless double-ended M26×3.0 Joiner Stud halfway into the Pommel Cap (printed upside-down flat on its top face), then screw on the Hilt Grip.

2. Upper Hilt Stack: Thread the Switch section (and any included Extension / Choke sections) onto the upper M26×3.0 male threads, followed by the Crossguard Emitter.

3. Crossguard Side Quillons: Screw the two upright-printed M12×3.0 Side Nozzles into the horizontal side ports on the emitter, then thread in the two Quillon Mini-Blades.

4. Display Plug or Full Blade: Insert the M22×3.0 Turbine Blade Plug for belt/desk display, or screw together the 4-piece Modular Blade and thread it into the top emitter socket. 

Customize & Mix With 80+ Interchangeable Parts

Because every part uses the exact same M26×3.0 mechanical interface, every section in this free starter build is 100% cross-compatible with all 80+ emitters, grips, switches, chokes, extensions, and pommels in our interactive WebGL configurator: 

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