Obi Wan Kenobi's lightsabers made a return from TPM. The story is that he constructed a new lightsaber identical to the original with a few modifications.
However the "real" story is, the original hero prop was missing from LucasFilm inventory. One of the stunt casting was chromed and painted to match
the original and slight modifications were made.

Anakins more closely resemble the ANH design. However orignal concepts suggest either a longer than normal legnth or a double ended saber.

There were a number of concepts for the Sith including making it a female character.
Throught the development, the curved hilt was a vision that made it's was to the screen

Here are the main character sabers used for AOTC