Thermoformed Light Saber | May The 4th Be With You
Celebrate May the 4th with a fun, functional, and highly customizable thermoforming project!
This Lightsaber-inspired container combines a detailed 3D printed handle with a thermoformed mesh capsule, perfect for holding candy, small gifts, or even LEDs for a glowing effect.
Designed with both aesthetics and practicality in mind:
The handle prints cleanly with no supports
The mesh insert is optimized for thermoforming
The system uses a simple snap-fit / press-fit assembly
Perfect for:
🎁 Party favors
🍬 Candy holders
💡 LED light props
🧪 Learning thermoforming
⚙️ Features
Modular design (handle + insert)
Multiple color variations (mix & match!)
Lightweight but sturdy
Optimized for fast prints
Beginner-friendly thermoforming geometry
🧰 Print Settings
Handle (Main Body):
Layer height: 0.2mm
Infill: 5%
Supports: ❌ Not needed
Material: PLA / PETG
Insert (Thermoform Mold):
Infill: 30%-40%
Material: PLA (recommended for shaping)
🔥 Thermoforming Guide (Simple Method)
Print the insert mold
Heat plastic sheet (PETG or PLA sheet)
Press over the mold (manual or vacuum forming)
Snap into handle
💡 Tip: Use thin PETG sheets (~0.5–1mm) for best results
🎨 Customization Ideas
Transparent colored blades (like your red/blue/purple variants)
Add LEDs inside for glow effect
Scale length for mini or “double saber”
Swap mesh density for different looks
IMPORTANT
If you are using a slicer other than Bambu Studio, you need to configure the thermoform pieces (The ones called Form/Form(1)) correctly. In the Strength settings, adjust these:
The Infills in my profiles are as follows:
Gyroid 30%
Honeycomb 30%
Triangles 40%
Get it at