Unique Lightsaber Design and Production
Abstract:
This project aims to design and machine three different lightsabre hilts. I will be designing the
hilts during the summer and machining them at the beginning of the school year. Machining will
be supervised by Professor Roger Greener. This project will include 3D modeling, production
drawings, a bill of materials, and CNC programs with the required setup sheet. This project is
an effort to build my portfolio and make me a better candidate for other employers.
Larger Purpose:
This project is intended to provide me with experience in my chosen field as well as a possible job opportunity after graduation.
Project Goal:
The goal of this project was to design and create three distinct lightsabre hilts.
To achieve the goal, the project was worked on during the summer until it was ready to move to
the next step, fabrication, which could not be started until the school year had started. The
steps completed during the summer were the design of the 3 lightsabres, CNC program
creation, creation of production drawings, planning the setups, and purchasing materials.
Once the fall semester had begun and the CNC machines were available for use, the project
could move forward. The production plans were discussed with Prof. Greener who helped to
improve the machining setups and processes. From there, the fabrication of each of the
lightsabres happened on weekends throughout the semester. They were completed by
December 14.
Outcomes:
This project provided me with the experience of creating a full set of documents normally used
in a industrial setting. It also provided me with a great project to bolster my resume which will
assist in finding jobs in my field. I also got a custom lightsabre.
I was able to create a set production drawings needed for machining each of the lightsabres
using the same software I used to design them, Solidworks. These drawings are part of my
deliverables. I was able to include this project in my resume and portfolio. I also made 3
lightsabres by designing them using Solidworks, buying material, and machining them using the
SUU machine shop.
Deliverable:
The documentation for this project consists of production drawings, machining tooling and setup
as well as pictures of the assembly after fabrication. It has some information removed as it is a
proprietary part. It is all compiled into a PDF document.