Lego Star Wars lightsaber pen

Pen inspired by a lightsaber from Lego Star Wars

Files:

The hilt and blade (cap and body of the pen) are common for all refills.

The tips are specific for each refill. I have designed two, check the measurements of yours to see which one suits you best. If neither works, feel free to design your own. I have left the STP file to facilitate the task.

Tip - pilot.stl: “Pilor super grip” refill

Tip - generic.stl: “Generic” refill (Parker Ballpen Refill Imitation)

Materials:

For the grip any material works. For the blade and the tip I have tried PLA and TPU. With TPU it works perfectly and the texture is more pleasant. With PLA you must have the printer well calibrated if not maybe you should sand lightly to adjust the cap.

Print settings (some recomendations):

• Hilt
  • Tree support
  • 0.16 layer height
• Blade 
  • No support
  • 1.32mm wall thikness
  • Brim
• Tip
  • No support
  • 30 mm/s
  • 0.16 layer height
  • Brim

Tolerances:
The tolerances should be enough for the tip to fit tight on the blade and for the hilt to slide without applying too much force or falling off. If your printer is not well calibrated, maybe you should apply a negative horizontal expansion.