Single-Bladed, Dual-Bladed & Crossguard 3D-Printed Saber Assembly Guide
Part counts, hardware connectors, and step-by-step assembly order for Single-Bladed sabers, Dual-Bladed sabers, Crossguard sabers, and the 4-piece Modular Blade.
- Saber Styles
- Single • Dual-Bladed • Crossguard
- Pommel Connector
- Pommel Joiner Stud
- Center Connector
- Dual-Threaded Center Coupler
- Modular Blade
- 4 Interlocking Sections
1. List of Printed Parts by Saber Configuration
In the 3D Studio you can switch between Single-Bladed, Dual-Bladed, and Crossguard configurations at any time. The Complete Print Bundle (.ZIP) automatically packages every required connector and side quillon for your chosen build.
| Configuration | Hilt Sections to Print | Included Connectors & Blade Hardware |
|---|---|---|
| Single-Bladed Hilt | 1× Blade Emitter, (Optional Choke Neck), (Optional Upper Extension), 1× Activation Switch, 1× Hilt Grip Sleeve, 1× Pommel Cap | 1× Pommel Joiner Stud + 1× Turbine Blade Plug + 4-Section Modular Blade. |
| Dual-Bladed Saber | 2× Blade Emitter, (2× Choke Neck), (2× Upper Extension), 2× Activation Switch, 2× Hilt Grip Sleeve | 1× Dual-Threaded Center Coupler (joins both grips at center) + 2× Blade Sets / Plugs. |
| Crossguard Saber | 1× Crossguard-ready Blade Emitter (with side ports) + lower hilt + Pommel Cap | 2× Upright-printing Side Quillons + 2× Threaded Side Quillon Blades + Main Blade. |
2. Step-by-Step Assembly Order
Before final assembly, inspect the bottom edge of each printed part. If you printed with an outer brim or have slight first-layer elephant-foot squish, run a deburring tool lightly around the outer bottom edge so thread shoulders seat flush.
- Step 1 (Pommel Cap or Center Coupler): Thread the headless Pommel Joiner Stud halfway into the Pommel Cap (or thread the Dual-Threaded Center Coupler into both Hilt Grip bottoms for a dual-bladed saber).
- Step 2 (Lower & Mid Hilt): Thread the Hilt Grip Sleeve onto the Joiner Stud, then thread the Activation Switch (plus Optional Upper Extension and Optional Choke Neck) onto the top screw threads.
- Step 3 (Blade Emitter & Crossguard Quillons): Thread the Blade Emitter onto the upper stack. For Crossguard builds, screw the two upright-printed Side Quillons into the side sockets, followed by the two Side Quillon Blades.
- Step 4 (Display Plug or Full Blade): Thread in the Turbine Blade Plug for clean display, or assemble the 4 interlocking blade sections and thread the base into the emitter.
Test Any Combination Live in the 3D Studio
Mix 80+ threaded parts, inspect the screw threads in exploded view, and export print-ready .STL files.
Related Guides
Complete FDM and SLA printing guide for support-free modular saber hilts: slicer settings, why supports stay OFF, filament selection, and radial thread clearances.
Full mechanical specification for SaberCraft hilts: ISO metric M26×3.0 body joints, M22×3.0 blade sockets, thread lengths, and internal electronics cavity diameters.