I constructed it in Australia with my uncle and his lathe out of aluminum. The two halves screw together around an electronics core I purchased from LGT, on Aliexpress. The core controls the blade, and sound effects. The nub on the end of the hilt connects into a belt clip from Disneyland I modified and painted.

The Process

Beginning with a sketch of my general idea, I transformed it into a flat layout of the final form. The aluminum round bar stock was cut to length, and had threads added to it across the two parts. The top half was faced down on a lathe, and had knurling added to the button section. It then had holes marked and drilled out for the slots at the emitter end. Using an angle grinder, more material was cut away to create the full lines. The bottom half was machined down on a lathe and then using large files to create the smooth curves. The nub on the end was machined on the lathe, filed at its base to match the curvature of the hilt, and screwed into a tapped hole on the hilt.