This sword took about 1 month to do, though I was distracted with other props as well.
For this sword I used the 3D file provided by Jackarage as seen here: [link]
Everything but the blade and jewels were 3D printed. The blade uses 0.5 inch thick poplar wood. I casted the 2 blue gems with Tap Plastics Clear Cast Resin.
I will be doing a full write up/guide on my website Soynuts Props
in the near future. You can also see progress pics on my FB Fan page: My Facebook Fan Page
Here is a close up shot of the hilt: [link]