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Introduction to SolidWorks and CAD
Lightsaber Hilt
As part of a semester long introductory to CAD thru SolidWorks I built, assembled, and 3D printed a lightsaber hilt and clip
Design Process
Hilt Design
Exploded View and Drawings
Hilt Design
Every good lightsaber design starts at the Hilt. Given some physical restraints and a list of parts I would need to create, I began working on the outer housing of the lightsaber. This served as a benchmark to ensure future components would fit
Crystal
Exploded View and Drawings
Hilt Design
The PowerSource. I used a combination of lofts, bounds, and extruded cuts to create a non-uniform crystal. This made for a more challenging crystal housing design to hold the crystal tightly in place
Exploded View and Drawings
Exploded View and Drawings
Measurements and Tolerances
We quickly learned to document our process and start adding pieces to an assembly file. From the assembly I learned to explode views. In drawings I learned to capture these views and label them. This is an exploded view of the forward assembly of the lightsaber, all pieces designed to fit into the hilt
Measurements and Tolerances
Measurements and Tolerances
Measurements and Tolerances
Learning the tolerances that we would need to design for was an important part of our final project, assembling the pieces from 3D prints. The picture above is the compiled forward assembly drawing, with important measurements and tolerances noted. Several views and a breakaway cut out are pictured.
Final Hilt Design
Measurements and Tolerances
Final Hilt Design
The final hilt came together beautifully. The exploded view shows how all the pieces fit together.
3D printing
Measurements and Tolerances
Final Hilt Design
Issues arouse during the 3D printing. A small number of 3D printers and a large class size allowed for only one submission. Some of the parts came out pristine, and some other parts didn't make it past support separation. I was able to get several pieces together and still have my first 3D print.
Results
The resulting print was awarded with full points due to circumstances beyond our control forcing an incomplete build. But I wasn't satisfied. That month I purchased the first of several 3D printers. The learning of SolidWorks and slicing software started an additive manufacturing fire in my heart that still remains. To date I have made hundreds of 3D prints from personal CAD files. The result of this class was much more than teaching me a foundational skill, it brought my love of engineering into the real world and gave me tools to create.
Reflection and Lessons Learned
John Carey Engineering - Your Partner for Mechanical Engineering Excellence
What I learned - This project taught me foundational knowledge of 3D design, CAD and additive manufacturing. I learned the basics of sketch tools, feature creation, parametric design, assemblies, and drawings. This project gave me the knowledge and confidence to continue my love of additive manufacturing beyond the scope of this class. It taught me to use slicing software, how and when to use supports, and how to export the process from CAD to a 3d printer.
What I would do differently - Given the chance, I would incorporate more outside learning into my curriculum. YouTube has been instrumental for me to learn new design techniques, dial in 3D print settings, and introduce me to new features of SolidWorks. I would have tried to learn complimentary knowledge as I learned the basics. Additionally, had I known what that this project would inspire me to 3D print at home, I would have ordered a 3D printer to be used during class time. To see my designs come to life real time would have been inspiring and helped me bridge learning gaps
The Future of this Project - After this class concluded I never went back to reprint this project. This files live on a computer I still have access to. Now that I have more advanced 3D printers at my disposal I would like to revisit this project and print out the pieces that failed the first go around. Then do some finishing on the final product and display it.
