Lightsaber Hilt

CAM Machining Welding
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Overview

A passion project turned machining masterclass. I designed and machined a 7-piece lightsaber hilt from brass, stainless steel (SS316), and mild steel to sharpen my CNC lathe and mill skills. The project tested my problem-solving—leading to welding, heat treating, and material upgrades. After 50 hours of design, planning, and machining, it is now my living room's centerpiece.

Technical Details

  • Components: 7 machined parts (brass, SS316, mild steel)
  • Software: CAD and CAM in Fusion 360
  • Machining Process: CNC lathe & CNC mill
  • Heat Treatment: Self-taught heat treating process for durability
  • Scrap Rate: 2 failed hilts before a final successful build
  • Time Investment: 50+ hours

Development Process

  1. Design & Programming: Modeled in Fusion 360, generated toolpaths for CNC machining.
  2. Machining & Challenges: Cut and shaped components on CNC lathe and mill.
  3. Material Issue: Discovered galvanic corrosion on mild steel due to dissimilar metal contact.
  4. Solution: Upgraded all mild steel components to SS316 to eliminate corrosion.
  5. Learning & Repairs: Heat treated parts in my garage and welded a threaded rod after a tap broke.

Results

  • Functional & Durable - Eliminated corrosion issues with full SS316 construction.
  • Hands-On Learning - Improved machining, heat treating, and welding skills.
  • Personal Achievement - A handcrafted centerpiece in my home decor.