A pirate, knight in shining armor or a ninja costume is better with a sword for a prop. Halloween costumes that are homemade are better since you put some of yourself and your creative ideas into the costume. If your costume needs a sword to complete the costume you can make your own with some cardboard cut out into the shape that you want your sword to be. First decided how big you want your sword to be. It is important that your sword is not too big that it takes the attention away from the costume unless that is what you want it to do. And if your sword is too small it may not get noticed very much.
Once you decide on the size of the sword decide on the shape of the sword. Draw it out on a piece of newspaper and you can use the newspaper for a pattern. Cut out the shape and decide if you are happy with it. If you are you can copy the shape of the sword onto your cardboard.
You want your sword to be somewhat sturdy. You may want to use two pieces of cardboard glued together for the added strength. Lay your newspaper cutout on the cardboard and trace the newspaper. Then cut out the cardboard.
Once you have your sword cut out of the cardboard you can cover the cardboard sword with some aluminum foil or some duct tape. Aluminum foil is nice because it is shiny but it is hard to attach onto the cardboard. Duct tape is easy to attach onto the cardboard but it is not as shiny as aluminum foil.
If you use the aluminum foil you can use some glue to attach the aluminum foil onto the cardboard. Or you can wrap the cardboard with the aluminum foil so that the aluminum foil stays on the cardboard securely.
If you decide to use duct tape to cover your cardboard then you can wrap the duct tape onto the cardboard so that it sticks onto the cardboard and does not come off.
You can make a round piece of cardboard that fits on the end of the sword to protect your hand and cover it with aluminum foil or duct tape for an added feature to your sword.
A Halloween sword made of cardboard is easy to make and lightweight to carry around with you on Halloween.