BROADSWORDS

BLOOD OF MY BLOOD | SEASON 2 (2026) | Sony Pictures LTD

These 15 broadswords (3 different basket styles) were made using PU rubber baskets and handles mounted onto a CNC’ed clear plastic blade. These soft swords were made for horse riding as well as battle scenes. The baskets and handles were cast in moulds taken from originals. A threaded channel was then created into the bottom end of the blade cut-out to secure the elements together using a dome bolt.

A further 15 different broadswords were made using a CNC’ed plastic basket template that was then heat formed over a wooden former and secured using the method mentioned above to the handles and blades.

The paint finish on the baskets was achieved using a gloss black base coat followed by a graphite spray (buffed) and finally a dusting of Pro Chrome paint.

The handles were painted using a combination of spray paints and sponged on acrylics to create a leather like finish.

The blades were primed with a metallic grey and finished with several layers of Pro Chrome.

Here are some images of the moulds I made of all three basket type. Due to the complex shape each mould consisted of at least 4 parts as well as multiple vent holes to ensure the PU rubber was able to reach into every section. They often cast in multiple pours, rotating and then resting the mould at different angles. The thinest sections of the steel were build up using clay before moulding to make the casting process easier and avoid blockages.

Moulds: Silicone with a reinforced Jesmonite jacket.