Darth Malgus' Lightsaber

This is Darth Malgus's lightsaber first appearing in the StarWars: The Old Republic game. I based this design off of a few images online, and some Old republic trailers. This hilt is a behemoth coming in at around 15" (380mm) long and about 180g of filament. I was going to color the blades (black with a silver bezel) but it got a little ridiculous in the amount of filament it would have wasted. Still - if anyone wants the two colors - let me know and I will set up the part.

Like most of my designs, this hilt is designed to print and play. All parts are screwed in or interlocking; you will not need glue. I have set the seem lines to be as hidden as possible and plate 1 has been set up by object to save on time, filament swaps, and to keep the grip section steady due to it's height.

A word of caution before you get started. A lot of parts are press fit and threaded. SILK PLA is very brittle and weak compared to regular PLA. When you are assembling this saber, I would suggest you oil the threads a little to reduce friction (knife oil, gun oil, motor oil, mineral oil, ANY OIL). For the upper assembly with the blades, I sprayed everything down with ammonia free glass cleaner - it makes things slide together easily (and easy to clean up).

Filaments used:

• ZIRO silk PLA -Red
• ZIRO silk PLA - Silver Black
• Sunlu silk PLA - Gold
• Elegoo PLA+ - Black

Print Settings:

• 0.16mm layer height
• 3 walls for threaded parts, 2 walls for everything else
• 20% infill for threaded parts, 15% for everything else

Notes:

• Supports used on pommel and axe blades.
• Brims have been set on the activator parts (due to a couple thin walls) and the grip (for stability)
• Smooth PEI hot plate recommended.
• Refer to the attached pictures for assembly.
• This was designed to print on a Bambu A1 - I have included the .3mf project with my settings