The main ingredient of this prop is obviously foam board, specifically extruded polystyrene, or insulation foam board. This comes in several flavors. The most popular option that I've seen seems to be 'Pink board', which is Owens Corning brand, but you can use DOW blue board or Pactiv green board. For our purposes it makes no difference.
It also comes in different thicknesses, so you can buy whichever thickness is most appropriate for your sword. Depending on the thickness you get you're probably looking at spending about $15-30 per board, but they come in 4'x8' sheets so you can make tons of swords!
Tip for those more frugal prop makers out there: If you only need the one sword, find some friends who need costume weapons as well and split the cost. Or check with local builders or suppliers to see if they have any damaged sheets they might be throwing away or selling for cheap.
Aside from the foam you will need:
-A Saw (very fine-toothed)
-Sandpaper
-Paint
An Aside: For this particular sword I used some scrap foam I had on hand and had to glue two pieces together. If, for any reason, you have to do something similar be careful what kind of glue you use. You need something pretty heavy duty, but certain glues can eat away at the foam. The one I used is some construction adhesive I had on hand called QB-300 but I'm sure there are other things out there as well.
![Cosplay Foam Sword Cosplay Foam Sword](https://www.knivesdeal.com/thumbnail.asp?file=assets/images/WARFOAM2D3SI856XC-2.jpg&maxx=400&maxy=400)
Foam Swords Home Foam Swords Page 1 of 2 Filter by: All Foam Swords Abyss Accurate Action Age Ages Anime Anubis Attack on Titan Awake Axe Bankai Barbed Bat Battle Black Blade Bleach Blood Boy Century Chaos Charm Christmas Classic Claymore Co Color Comic Comicon Con Convention Conventions Cos Cosplay Cosplay.