Tonfa Lightsabers
Fall 2025 During the 2025-26 school year at RISD, I was investigating occidentalism and orientalism as part of my thesis. One of the objects that caught my attention during this investigation was that of the tonfa. The distinct T shape of the tonfa is commonly associated with police baton sticks particularly in the states, but the actual country of origin is Japan. At this point in my research, I was also investigating elements of cooption within the realm of science fiction, and particularly how Star Wars borrowed heavily off of Japanese aesthetics and practices. As such, the idea of a lightsaber tonfa as an experimental layered object of cooption came into being.
The cope cut joint forming the ninety degree junction proved a challenge in the construction process. I experimented with both manual machining and CNC processes in order to achieve the cope cut. Ultimately the CNC method yielded more reliable results. The cam process for both the workholding and actual cope cut are shown on the right. Another part that required adequate replicability were the control boxes which were also done via CNC.
The majority of the saber was manually machined on a Southbend lathe and Bridgeport milling machine.
Each tonfa consists of 18 individual parts as follows:
-Emitter
-Emitter Flange
-Chamber Neck
-2x Brass Rings
-Main Body
-Control Box
-2x Brass Bars
-Shine-Through Glass Accent
-Rear Body
-Pommel
-Pommel Spike
-Cope Cut Joint
-Tonfa Handle Retention Ring
-Leather Wrapped Tonfa Handle
-Tonfa Cap
-Shine Through Actuator Switch