MakerBot Print is our newest print-prepration software, which supports native CAD files and STL assemblies,
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I have printed 1 Print-in-place version, 1 Stand alone hilt, and 5 blades. All using Ender3, eSun PLA+ @210 deg., 0.1 Fine Layer height, wall width 0.4 (my nozzle size) with 2 walls (resulting in 0.8 thickness). Yes, it takes FOREVER to print. After reading this thread about fragility, I decided to test my saber. Using my hilt and a blade, I dropped it on a cement basement floor, held at shoulder height (I'm 6' tall), several times with both the blade extended and retracted. No drops resulted in it breaking in any way. Not even a chip. I also realize kids will be far more hurtful to these, so I decided to start whacking things with it, as if I were a kid playing with a sword. I had to whack pretty hard against the edge of a door jam to damage the blade. It dented in but did not split.So, either I am lucky or you are not, but I find this design to be more than adequate.