How to Make a Lightsaber Blade

How to Make a Lightsaber Blade?

If you or anyone you know happens to be a huge Star Wars fan, you have probably wondered how to make a lightsaber blade on your own. Well, you are in luck! This article will walk you through the steps of how to make a lightsaber blade so you and your friend can live out your fantasies safely and comfortably.

Best Materials

Best Materials


While the true lightsaber uses Plasma energy to cut through nearly everything, unfortunately, we will not be using that to make a lightsaber today. But, given that the sheer presence of the lightsaber is enough to reach the souls of even the non-Starwars universe, we can create a friendly and safe version of it ourselves!

To make a lightsaber, you will require the following

  • Polycarbonate (PC) Tube 30-36 inch with a 1-inch OD (Outside Diameter). The wall of the tube should be ⅛ of an inch thick
  • A cap to cover the end of the tube (this will be the blade tip)
  • Glossy material such as cellophane (Blue or Red, depends entirely on which side of the Force you feel)
  • 2-3 inch portable flashlight (the brighter, the better)
  • Paper towel or toilet paper roll
  • Clear tape
  • Black tape
  • Double-sided tape (Optional)
  • Measuring tape and ruler
  • Coloured foil paper (Optional)
  • Jewels, gold plates, etc. (Optional)

A Jedi tends to use a 3-feet-long lightsaber. However, if this is your first time assembling a lightsaber and ideally wielding one as well, we would recommend you have another person alongside, just in case. Now that you have the resources you will need, it is time for us to make a lightsaber blade.

How to Make a Lightsaber Blade by Make This Procedure

How to Make a Lightsaber Blade by Make This Procedure
Now comes the important process; the assembling of the lightsaber blade. Please do follow the instructions properly to get the desired finish.

Step 1- You want to measure out how long you want the main tube to be. We would recommend having a 30-36-inch-long tube and cutting it down to at least 20-26 inches. However, if you feel up to it, feel comfortable keeping the length as is!

Step 2- For a smooth surface, you may have to sand the tube with 800-1000 grit fine sanding paper. The smoother the surface, the cleaner the finish

Step 3- Before assembling the lightsaber, check the fitting of the PVC cap. The cap should cover the top of the tube, hugging it tightly enough to not let the light rays shine beyond where it is supposed to. This step is recommended after the sanding to ensure the right fit.

Step 4- Now, you must measure out the right length of the cellophane. The cellophane must cover the whole length of the tube but not the cap. The cap will be its own entity. The cellophane will be used to add a shiny exterior to give it that ultra-shine when you position the flashlight.

Step 5- Now comes the wrapping of the cellophane. To do this, lay the measured cellophane down on a flat surface. Make sure to smooth out the wrinkles properly. Then place the tube on one end and start wrapping. Wrap it tightly a couple of times to give it the ideal finishing. Be sure to start off on a dust-free surface to ensure no dust particles show up on your lightsaber. Once tightly wrapped, you have 2 options.

You could either wrap the cellophane around tightly and secure it with clear or double-sided tape. Or you can use the cap and seal the end of the tube. For either of these to work, you must wrap it around as close to the tube as possible. Remember, do it slowly and safely. Do not rush.

Step 6- Now comes the coolest part-the flashlight. In order to ensure the whole of the tube is lighted when the flashlight is turned on, you want to ensure you are positioning and setting the flashlight correctly. To do this, turn the flashlight on and place it at the open end of the tube. Then secure the tube to the flashlight with black tape. You will know the flashlight has been secured properly once you can raise the tube just by holding the body of the flashlight.

If needed, secure it with more tape, or you may even shorten the tube. Turn the light on a few times to test how the tube looks both in daylight and in the dark. Flashlight rays do not go that far, unfortunately, in which case you may wrap the tube in more cellophane or even a colored foil to give it a shinier appearance.

Step 7- After the flashlight has been secured to the tube, take a toilet paper roll or a paper towel roll (depending on the length of your flashlight) and create incisions according to the design of the flashlight. This will enable you to turn the flashlight on and off, depending on your choice. Once you have created the incisions, secure them onto the tube with a little black tape.

In a similar fashion, test the security of the roll to the tube. You must ensure it stays on as you move your lightsaber (After all, you do not want your hilt coming off as you fight the other side). Once it is on, your hilt is almost complete.

Step 8- Now comes the decorative aspect of it all! You can paint the hilt according to your color of choice, and if you wish, you may even glue on jewels, gold plates, etc. Make sure whatever you do, the tube has been secured to the roll and flashlight, and you can hold the hilt comfortably. After this, you are done!

Final Words

to Make a Lightsaber Blade

The whole process of how to make a lightsaber blade is fairly simple. For further inspiration, we would recommend searching up pictures of lightsabers as you assemble yours. Always remember to have a smooth surface while doing this, which includes bumps, dirt particles, and wrinkles. Also, a good black tape allows for a stronger hold so you can comfortably wield your lightsaber around!