Blade Engineering: Polycarbonate Grades & Combat Suitability
Saber electronics
The performance of a lightsaber is defined by the "Strength-to-Weight" ratio of its blade. At replicasabers.co.uk, we utilise industrial-grade Polycarbonate (PC), a thermoplastic polymer known for its high impact resistance and optical clarity
Material Science: Why Polycarbonate?
Polycarbonate is used in bullet-resistant glass and riot shields because it does not shatter upon impact. Instead, it flexes, absorbing the kinetic energy of a strike. For Saber Engineering, this material allows for a blade that can withstand high-velocity duelling without compromising the safety of the electronics.
Mid-Grade Blades (1.8mm Wall Thickness)
Mid-Grade blades are engineered for speed and visual vibrance.​
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Physics
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The thinner wall allows for higher light transmission, making the colors appear more "saturated.​
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Application
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Ideal for Xenopixel V3 systems where the internal LED strip is the primary focus.​​​​
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Suitability
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​Best for cosplay, theatrical flow, and light-to-mid contact sparring.
Heavy-Grade Blades (3mm Wall Thickness)
Heavy-Grade blades are the industry standard for "Full-Contact" duelling.
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Physics
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The increased wall thickness significantly raises the Moment of Inertia, making the blade feel "heavier" and more realistic in a clash.
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Application
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Most commonly paired with RGB V2 systems. Because the blade is hollow, the extra 1.2mm of polycarbonate provides the structural integrity needed to survive strikes against other heavy-grade blades.
Suitability
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​Competitive duelling and heavy combat.
Technical Specifications: Mid-Grade vs. Heavy-Grade Blades
Diffusion Technology: Lighting the Path
Inside every blade (especially for RGB V2), we use a specialized Diffusion Film. This film is a micro-textured wrap that catches the photons from the hilt-LED and scatters them evenly. Without this engineering, the blade would look like a dim torch rather than a solid beam of light.