What makes a lightsaber ‘duel worthy’? A duel worthy lightsaber is a lightsaber that you can use in full contact sparring. Full contact lightsaber sparring is pretty rigorous and demanding. A lightsaber needs to be both durable and safe if you are going to use it for full contact dueling.
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To determine whether a lightsaber is duel worthy, one of the first things you need to examine is the material of the hilt. Some people sell PVC and 3D printed lightsaber hilts on eBay and Etsy and those are probably not going to be durable enough for dueling. Although aluminum is one of the most common lightsaber hilt materials, not all aluminum hilts are duel worthy. For example, The Pach Store’s Darth Nihilus inspired Unicron hilt is thin in certain areas, so The Pach Store advises that the hilt is only suitable for light dueling.
Another aspect of this hilt to consider is edges and points. Some hilts and hilt components have sharp edges and points that could cut or poke you or your opponent during a duel. Some dark side lightsaber hilts use in particular use claws around the emitter area. Avoid hilts and hilt components with edges and points during full contact dueling.
The lightsaber blade also weighs heavily into a lightsaber’s duel worthiness. As with lightsaber hilts, the material of the lightsaber blade matters. Flat acrylic blades, are show blades and not for dueling, because acrylic is a brittle type of plastic. Some acrylic lightsaber blades also contain sharp edges or points. Ripper Blades [AFFILIATE LINK] is the largest and most famous flat acrylic lightsaber blade maker and Ripper Blades advises on their website that the flat acrylic lightsaber blades are not for dueling. The acrylic blade featured on the far right of the image was made by eBay seller sdalton256 (Sactown Sabers) [AFFILIATE LINK].