I'm not talking about the blade but the hilt. For the blade I use already pre-formed polycarbonate (I think).

I take the (now no longer available) Hasbro ultimate FX lightsabers and re-purpose the blade & electronics. I change the LEDs to whatever color I want, add some form of connectors to the electronics board, and print a new hilt.

With every PLA I've tried (about 20 different types from various manufacturers), when the blade is hit against something with medium force the hilt cracks along layer lines. With cold vapor smoothed ABS that doesn't happen (unless some part of the hilt is thin-walled)... plus get the advantage of removing most layer lines.

I don't see how tape would help all.