A chassis I think would work better then just a tiny screw at each connection.
Either way cool idea.
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I think I should explain my idea a little bit more.
First, I would never even consider a tiny screw, I was thinking about a locking twist connection at each junction point. Think of the way a medicine bottle locks, the cap twists on and snaps into place. This is my idea for the connections.
As for the modules themselves, I’m thinking of cylinders that contain the electronics, most of which would have some sort of material on the inside to absorb some of the impact force from the blades hitting each other. The batteries could then ditch the standard design and instead be more like a modern cell phone battery, that is designed to fill a space, that space being a two or three inch tall battery cylinder. The speaker could then be placed at the end, with its own enclosure, and the possibility of a small LED module at the end for some interesting effects from the pommel.
The switch module would have to have a track in the side of it for the switch, this is the only module I think would need to be installed from the factory. That is unless there could be a simple way to install a switch without any wiring needed.
As for the LED module, it would snap into place at the tow of the saber, and have some sort of damping material around the LED to keep it from bouncing around too much. This would also allow us to replace an LED in seconds instead of minutes or weeks. Simply snap the LED out, and snap in a new one. This way we could have multiple different colored LEDs for our sabers. Either that of a HEX, QUAD, or TRI LED module. HEX has red, green, blue, amber, white, and UV in one diode, so there could potentially be three or four diodes in each module making the blade even brighter.
If you have any questions about HEX LED, simply go to YouTube and search the phrase.
Anyway, I hope I explained my idea a little more clearly. If you have any questions about my idea, feel free to ask.
And as always, may the force be with you.