Outside dimensions were referenced from a schematic from Martin Taylor. Chamfers and fillets were added in areas to strengthen design. Lightsaber is hollow and will house electronics and lights when I am done with it. I included the fusion 360 achieve file and a .step file so that you can edit it if you wish.

Total parts to print: 5-7 (Depending if you print the tube mount and the battery lock)

Build size
Largest part is a little less than 5in tall. Which will fit on most printers I know and work with. Some threads can be removed to reduce that size.

Supports
There are duplicates of the parts that require supports. You can choose to use the supports I generated with Meshmixer or you can take the files without the Supported prefix and add your own supports.

Blade
For my lightsaber I am using a 5ft x 1in OD tube. The nylon tube I am using doesn’t thread easily and is thin so there is a tube attachment with threads on it. Print it and force it onto the bottom of the tube. Light sanding of the tube may be required.

I found a good link for tube in this pdf:
http://www.hyperdynelabs.com/docs/hyperblade/HyperBlade%20saber%20blade%20kit.pdf
They recommend two different tubes. One for the inside led blade and another for the outside blade.
Outside tube: http://www.mcmaster.com/#8628k67/=10fuu6s
My current design only accounts for the outside tube. A small change to the Tube Attachment can allow for both tubes.
They sell it in 5ft length. I cut mine down to around 3ft (according to some forum posts about blade length).

Battery
The RidgedHandle component is designed with the intention of housing a 18650 rechargable battery (~67mm x 18.8mm OD). There is enough room on the sides of the battery to run wires past it.

USB
Ordered from Amazon: http://www.amazon.com/gp/product/B00R3B0AOK?psc=1&redirect=true&ref_=od_aui_detailpages00
Mounts into bottom section. With threaded cap to protect if from dust when not using.
The bottom also uses left-handed threads, so that you can undo the usb cap without unscrewing the entire lightsaber.