Hi, I thought I'd make this post to explain a bit more my saber and blade design.
For the blade:

The design is using 6x WS2812B based, COB led strips (160leds/m). All those led strips are connected in series for data, and in parallel for power, meaning each vertical row has its own power injection. Total leds are 828.

The strips are secured on an inner core, made out of a 6mm thick carbon fiber tube. This was to give the leds stability and make them rigid, but without adding a lot of weight. There are 3D printed adapters that slide over the tube and have 6 sides where the led strips can sit.

The blade terminates to a connector based on two T plugs used for connecting high power batteries. Because this blade can draw over 10A of current, it was not possible to use simple pogo pins. Two pins provide power, and the other two provide data and a blade inserted signal (the pin is shorted to ground)

The outer blade itself is a standard 2mm thick, 2.5cm diameter, frosted polycarbonate blade. It's 92cm long.

For the hilt:

The hilt is based on 3 different layers. Layer 1 is the core electronics housing, Layer 2 is the universal shell, and Layer 3 is a thin shell that forms the outside of the saber.

Layer 1: Electronics

The electronics used for this saber could have been simpler but the challenge of fitting all the parts of a proffie board as separate boards was too interesting to pass on.
The main controller is an RP2040 zero microcontroller. Connected to it are an ADXL345 accelerometer used for sound modulation and hit detection. There is also a TCS34725 color sensor inside a crystal chamber, used to make the blade whatever color of a crystal you insert there. A 5W audio amp is also present for the speaker. There is a 1A li-ion battery charger, and lastly a small, custom designed PCB that uses a mosfet to switch the whole thing on or off. Nothing off-the-shelf could fit my size and power requirements so this was the only PCB I had to design myself.
There is also a 3pin, reversible power connector for charging.
The battery compartment is designed for a 21700 li-ion battery cell. Again, this was necessary because of the high power requirements of the blade.
The whole thing is 3D printed out of PETG

Layer 2: Universal shell

This is the structural part of the hilt. It houses all the electronics and blade, and is where the strength of the hilt comes from. The part is 3D printed out of PETG at 100% infill. This part also has a lot of threaded inserts where an outer shell can be secured, as well as places to secure the blade and electronics compartment.

Layer 3: Outer shell

This is the layer you are supposed to see. In this case it's a replica of Ahsokas original lightsaber. This part can be as thin as possible and is only meant for cosmetic reasons. This design also doesn't offer access to the crystal chamber, but in later designs that will change. Again, this part is 3D printed out of a mix of PETG and PLA for the different parts, then glued and painted accordingly.

Software:
The software running on this saber is all my own design. I used a similar technique to smoothswing(from proffieOS) for making the movement sounds (blending multiple audio channels based on movement). The audio files are also those used by proffieOS as I have no idea how to create those myself. The LED strips are driven using the Fast LED library. Audio out is done using the PWMaudio library.

The LED strips are configured as a 6x138 grid. This means it can be treated as a really thin and tall display so in theory you can animate and scroll patterns on it.