1) why wouldn't it break per impact? 2) does it really make those sound? or did someone add the sound after the video is filmed? 3) how do the saber knos as per ea. contact, the light changes and w/ the growing light?
Current lightsabers for sale (like Ultrasabers and Saberforge) use polycarbonate blades, LED lights in the high grad aluminum hilt, and a semi-transparent surface in the blade to keep the whole thing lit. They generally had a good, but tiny sound card/speaker and sometimes a light/effect card in the hilt with batteries to power them. They are rated for "combat" meaning they can take full force blows repeatedly with little wear. I own several from Ultrasabers. This is me messing with the Emerald driver, which changes the color of the blade (via a program. You have to plug in the saber to a computer to do the adjustments between changes. There are newer Diamond drivers that allow you to change the color configuration between multiple presets. I have one of those but have never really messed with it).
impressive idea, to have a PC to control the sound card, never thought of that but at that 1st video, they smash ea. other really hard, the material can hold in the long run?
Polycarbonate is VERY strong and flexible. So long as you're mainly hitting it with just more polycarbonate, then it'll hold up just fine. Indeed the more likely point of failure isn't going to be the tube itself, but the connection point to the hilt.
Or the end cap will come off - I had that issue with one of my Ultrasaber blades, and I don't even engage in fights.
Which sounds like a problem with the adhesive breaking down rather than the polycarbonate itself. I've never really looked into it, but one assumes the tips are a separate piece that gets bonded on, as manufacturing a semi-enclosed cylinder is way more complicated than manufacturing open tubes and then capping them. I wouldn't be shocked if at least some of them just have silicone rubber tips for safety.
They are a separate piece. Depends on the bond on them if the cap holds or not. You can get rounded or pointy depending on how you want it to look. Some have recently come out with a thinner blade to look more like the Rebels aesthetic.
I doubt Ultrasabers would sell those - too much risk of eye damage. I gave myself photokeratitis a few years back that left me unable to see beyond fuzzy shapes for a day or so just looking occasionally at a UV light source without eye protection. I would not recommend it.