A chassis for Korbanth's MPP 2.0 (possibly newer versions) Vader Lightsaber prop. I wanted something printable with as little support as possible, something that looks Vader-esque but not over the top with filigree. 

Initial efforts with FreeCAD were difficult due to the amount of variables, and FreeCAD's spreadsheets were too slow to update at the time. 

I ended up switching to openSCAD which made the job a lot harder but I'm pleased with how it turned out. Uploading here for anyone to improve or modify. 

I dont really have any build instructions but from the pics it should be pretty self explanatory to most people attempting to tackle this. 

Printing:

I printed the main bodies in black PLA+, and the crystal chamber elements in ABS like resin.

All the FDM parts can be printed without any additional supports. 

 All the grilles were lined on my example with a steel mesh just for looks.

Crystal Chamber:

I used a quartz crystal from amazon, each chamber endstop has a space for a 5mm LED  so use at your discretion or modify the scad for a 3mm etc. Push together with the brass tubes (cut to size , you will have to experiment with fit and total length).

Rear Chassis:

Speaker goes in the rear chassis just behind the crystal chamber, its an eccentric fit so wires can pass underneath. 

Card tray accepts a proffie 2.0 which on mine I just press fitted in. Theres 2 rings on the bottom to accept a rice port and a charge jack. 

The STL has the access door missing with a supporting piece added, once printed it should be easier to remove than generated supports 

Glue the access door's clip to the stop , the door's lip should face downward.

Front Chassis:

Theres space to push an 18650 all the way to the top with a channel for wires. The cap was initially designed for the KR sabers pogo pin top cap, but I switched to a GX16 connector as I found it unreliable. once fitted it can be glued together. Switch wiring passes out the holes on the bottom ring piece with the tie fighter looking emblems. I had to cut a channel in the hilt thread to pass the wires to the switch, I didnt want to use the top switch as supplied , but up to you.

The code is supplied if you want to modify or adapt to another project. 

*** Note for SCAD ***

The code is somewhat messy - nearly everything is a variable at the top of the file, but I did get lazy at times so some magic numbers will probably be in there.  Its not really set up for easy customisation but most items are separate modules, and theres variables to control what parts of the hilt are rendered to some extent.