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HARDWARE PROJECT CASE STUDY

Saber Build

From whiteboard sketch to soldered, CAD-fitted handheld build, electronics, mechanical design, and integration.

Role
Solo builder
Focus
Interactive saber electronics
Stack
Fusion 360, LED strip, Tactile switch, Soldering, 3D print
Outcome
40+ solder joints across power, signal, and LED paths
View final build
IDEASSKILLSFINAL PRODUCTGALLERY
Hero visual / Final product preview

Original ideas

Where the build started

Early sketches and planning before soldering and CAD iteration.

First demo

Early handheld test before the final hilt finish — validating switch, LEDs, and basic ergonomics.

Fusion 360 CAD

Modeled hilt, emitter, and battery carrier in Fusion 360 — iterating tolerances for press-fit parts before printing.

Whiteboard circuit and hilt planning

Whiteboard circuit plan

Mapped power paths, LED segments, and switch routing on a whiteboard before the first solder joint.

Major skills

What the build required

The hands-on skills that turned the concept into a working object.

Soldering

40+ joints across power, signal, and LED paths — flux, heat control, and rework when pads bridged.

Lab testing

Checkout and safety testing in Detkin Lab before calling the build demo-ready.

Blade integration

LED strip segmentation and mechanical fit so the blade glows evenly inside the printed emitter.

Final product

The finished saber

A handheld build with working switch, segmented LEDs, and a CAD-fitted hilt — demoable outside the bench.

  • Working switch-actuated LED saber
  • Integrated assembly, not a bench-only prototype
  • Documented materials, soldering, and CAD process
Final media / Videos and images