Tony Stark is one crazy ridiculously smart dude. If anyone could find out how to make a Lightsaber, it would be him. Of course if he designed one, it would have to have his signature style and flair. That means it might look something like this impressive design by The Custom Saber forum user eastern57. The hilt even has an arc reactor (of course), and a nice pull apart section, and it also has sound effects.
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