Custom lightsaber
Custom lightsaber using Arduino Nano RP2040 and custom C++ firmware. 3D-designed and printed hilt. 40mm 5w 4ohm speaker, 3.7v 18650 lithium ion battery,
Creator · Electrical, mechanical · 2024-07-31 – 2024-09-10
Context
Off-the-shelf lightsabers lock you into someone else's choices: a fixed selection of effects, similar designs, no real room to customize. I wanted a saber I controlled completely, from firmware to hilt geometry. The core engineering challenge was fitting a microcontroller, IMU, battery, LED strip, and wiring into a narrow cylinder while keeping it all serviceable instead of permanently sealed inside.
Approach
I programmed an Arduino Nano RP2040 in C++ to drive interactive visual effects and audio, using a 6-axis IMU for motion sensing and addressable 5050 neopixel LED strips powered by a 3.7V 18650 battery. I designed the hilt in SolidWorks around the electronics, 3D-printed the parts, built a pull-out chassis to keep the board and battery accessible, and hand-soldered and routed the wire harness inside the enclosure.
Outcome
A fully working, motion-reactive custom saber that I can reflash and modify without tearing it apart. The build helped me improve my repair and troubleshooting skills for my lightsaber business, Hornet Sabers. It also taught me how to plan out and assemble in impossibly tight spaces and how to debug power and signal issues on embedded systems.