This custom Star Wars A New Hope (ANH) DL-44 blaster prop replica features lights, sounds, and interactive functions, finished in a weathered version for a more worn, used, lived-in look.
I personally designed this ANH DL-44 from scratch, and it ended up being one of those projects that took far longer than expected because I kept refining it until it actually felt right. A big goal from the start was to avoid the usual compromises of electronic prop builds, where you either end up with visible screws and access holes ruining the look, or the whole body gets glued shut and becomes a pain to service later. After a lot of redesigns, test fits, wiring changes, and plenty of trial and error, I finally landed on a version that keeps the outside looking clean while still allowing access to the electronics inside.
I also chose to build this around a Proffieboard rather than the more common Arduino Nano and DFPlayer Mini style setup. I have done a lot of testing with the cheaper electronics, and while they can work for simple projects, the overall experience is nowhere near as good. The DFPlayer clones in particular have a noticeable sound playback delay, and once you notice that trigger-to-sound lag it becomes distracting fast. By the time you start improving those cheaper setups with better parts, amps, and extra wiring, the cost difference starts shrinking anyway. The Proffieboard gave me a much cleaner, more responsive, and more premium end result, with better sound, better control options, and the flexibility to update sounds and behaviour later if needed.
The 18650 battery is hidden inside the grip, helping keep the outside of the blaster looking clean while still allowing access when needed. Charging is handled through a built-in USB-C charging port, and the required allen key is included for opening the hatch. The 18650 battery is also included, along with the display stand. The built-in USB charging is handy for topping the battery up, but it is fairly slow. If preferred, the 18650 can also be removed and charged externally, then dropped back into the blaster. The blaster also gives a low battery warning, so if you are at a convention or out for the day, you can quickly swap in another charged 18650 without any tools, which was another part of the design goal from the start.
The blaster powers on in:
Volume can be selected at startup:
This gives you a quieter setting for indoors, a standard setting for normal use, and a louder setting that is better suited to noisier environments like conventions.
This is a display prop replica intended for display, collecting, and cosplay use. It is not a toy.
Charging works through the built-in USB-C port and is intended for convenient top-ups, but it is fairly slow. The kill switch must be turned on for charging to work. The battery can also be removed and charged externally if preferred.
One of the nice things about this setup is that the electronics are not locked into this build forever. The Proffieboard can be reconfigured with different sounds and functions, and the electronics can also be recovered and reused in another prop or lightsaber later on if desired.
Please Note: All of my 3D-printed items are handmade and made to order. While I take great care in crafting each piece, slight variations or minor blemishes may occur due to the handmade nature of the process. Additionally, I strive to reduce the overall carbon footprint by recycling and repurposing shipping materials whenever possible. Rest assured, your item will still be safely and securely packed. Thank you for your understanding and support!