← Back to Projects
HardwareShippedFeatured

Lightsaber Build

CAD + circuitry + soldering to ship a handheld lightsaber build.

I used this as a hands-on integration project: sketching, CAD, soldering, wiring, and iteration until the final object felt robust in-hand and not like a fragile prototype.

Date
Spring 2026
Signal
Hardware
Build stage
Shipped physical build
Stack
Fusion 360, LED Strip
hardwarecadsolderingmechanical-design
Build snapshot
Lightsaber Build media 1

Project notes

Highlights

What I built

  • 40+ solder joints across power/signal paths.
  • Iterated CAD tolerances for fit and cable routing.
  • Integrated mechanical structure with functional electronics.

Architecture

How the system works

  • Battery and switch path drives segmented LED strip inside blade.
  • Printed hilt houses battery carrier, wire routing, and control switch.
  • Mechanical tolerances tuned to keep parts secure under motion.

Challenges

What made it hard

  • Wire management inside the hilt was harder than schematic planning.
  • Solder rework was needed when joint strength wasn't enough for movement.
  • Fit issues from early prints required repeated CAD adjustments.

Lessons

What I learned

  • Integration and packaging can dominate project complexity.
  • CAD tolerance choices directly affect electrical reliability.
  • Build quality is what turns a cool prototype into a real artifact.

Stack / materials

Fusion 360LED StripSoldering3D PrintingCircuit Design
  • Documented each stage from whiteboard circuits to final lab testing.
  • Next version could be battery-optimized with a cleaner internal harness.