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BATTERY LITH-ION 3.7V 2.2AH 1865
US Electronics Inc.
The Bytesaber: A Sharpie Holder That Looks Like a Lightsaber Hilt
2
2023-06-23 | By Zach Hipps
License: See Original Project
I have an impractical idea for a lightsaber hilt that can hold a Sharpie marker. My initial concept involves attaching the Sharpie to the hilt using the small shoulder found just above the marker's tip. To bring my vision to life, I started by 3D printing several samples with different diameters. I needed to find the perfect size that would create a good seal without drying out the pen. After a few tests, I discovered that a diameter of either 5.60 or 5.65 millimeters would work best. Ultimately, I settled on 5.65 millimeters as the ideal fit.
Now that the size issue is resolved, I can move on to designing the cylindrical hilt. My plan is to create a standard hilt that is interchangeable, allowing for the customization of different lightsaber styles. I intentionally left out the cool sci-fi-looking aesthetic because that would be accomplished later on. To accommodate the Sharpie, I extruded a hole into the top of the cylinder and added threads to allow for the attachment of different tops. This design feature would enable the creation of unique lightsabers by simply swapping out the top pieces.
Originally, I had planned to manufacture the hilt using aluminum. However, the high cost quotes I received discouraged me from pursuing that option. Instead, I turned to resin printing, which offered a more cost-effective alternative for this project. Nevertheless, I still want to explore metal fabrication using a metal lathe in the future.
I want to incorporate LEDs into the Bytesaber, so I designed a circular PCB with a hole in the middle, allowing the Sharpie to fit through while the lights would shine around it. The PCB featured four LEDs and four resistors, evenly distributed in a radial pattern to provide uniform lighting and was ordered through DigiKey’s DK Red PCB service. Powering the LEDs required a sufficient forward voltage, which couldn't be supplied by a standard AAA battery. I opted for a lithium-ion battery made from an 18650 cell which is known for its energy density. The standardized hilt needs to include a compartment to accommodate the battery and a cap to seal it. However, routing the negative wire proved to be a challenge. To overcome this, I created a slot along the inner wall of the battery compartment, allowing the wire to reach the negative terminal of the battery. One crucial element I need to address is how to incorporate a switch to turn the lights on and off without twisting the wires. I considered drilling a hole in the end cap, but it dawned on me that it would cause twisting whenever the cap was screwed on or off. This design flaw required further consideration and a creative solution.
In the meantime, I finished printing the interchangeable accessories to transform the standard hilt into the Darth Vader lightsaber. It has a really cool top shroud with a steep, cut-off angle and a very sinister grip with ribs running vertically. I spray painted the standard hilt with a metallic silver color, and at this point, I’m ready to work on the electronics. I applied solder paste to the custom PCBs I designed and placed the resistors and LEDs by hand. My reflow station made quick work of melting the solder paste and reflowing the components to the board. From there, I pulled some stranded wire from the top of the hilt into the battery compartment. DigiKey stocks 18650 battery cells with wires already soldered to the ends, but since I built my own battery packs before, I had a bunch of materials left over and decided to build my own. I soldered some wire to a small piece of nickel strip and used a spot welder to fasten the wire to the positive battery terminal. I did the same for the negative terminal but included a push button switch in line with the negative wire so that I can turn the LEDs on and off. At this point, I came up with a solution to the twisting wires problem. I needed to design an end cap with two lobes that mate with slots in the hilt. This way I can sort of use a twist lock mechanism to secure the button to the bottom of the hilt. I completed assembly by using hot glue to fasten the Darth Vader accessories to one standard hilt, and Luke Skywalker accessories to the other standard hilt. The project wasn’t complete, however. I didn’t want these awesome Bytesabers to just sit flat on my desk. They warranted a bent sheet metal display stand to hold the Bytesabers at a near vertical angle. And because there needs to be balance to the force, I included the Empire logo on one display while the other display had the Rebel Alliance logo just for fun.
Did I really need a nerdy way to hold my Sharpie collection on my desk? Of course not. But as impractical as this project was, I can’t stop smiling every time I reach for a Sharpie now.
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