Cutting & forming
Profile blanks from sheet and bar with the method that suits your geometry and volume.
- CNC machining centres
- Waterjet and laser cutting
- Hydraulic pressing and rolling
Everything a prop sword needs.
Under one roof.
Cutting, casting, forging, machining, plating, etching, woodwork, leatherwork, assembly and inspection — so a change to your specification never means re-quoting with a third party.
Six disciplines.
One production floor.
Casting & forging
Guards, pommels and ornate hilts reproduced from your original with fine detail intact.
- Lost-wax and sand casting
- Drop forging for blade tangs
- Rubber and resin moulding
Machining & assembly
Drilling, tapping, riveting and structural bonding that survive a drop without rattling apart.
- Tanged and pinned constructions
- Two-part epoxy and mechanical fixing
- Weight and balance tuning
Surface treatment
Metal and polymer finishes matched to a Pantone reference, a physical swatch or production stills.
- Nickel, chrome and brass plating
- Acid etching and laser engraving
- Bluing, blackening, powder coating
Hand finishing
The stage machines cannot do — polishing, wrapping, painting and ageing by hand until it reads as real.
- Leather, cord and wire grips
- Airbrush weathering and battle damage
- Mirror polishing to brushed satin
Wood & leather shop
Scabbards, sheaths, belts, plaques and stands made as matched sets rather than sourced in.
- Hardwood shaping and lacquering
- Leather cutting and saddle stitching
- Velvet-lined display boxes
We match the material
to the job.
A screen prop, a collector's piece and a LARP weapon have different enemies. Here is how we choose.
Steel — stainless, carbon, mild
For hero props and display replicas where the weight and the ring of metal matter. Edges are always radiused blunt.
- Blunt edges and rounded tips as standard
- Etched, plated, blued or mirror polished
- Best for: hero props, collector replicas, wall display
Aluminium — light and safe on set
Roughly a third of the weight of steel, so a long blade can be swung repeatedly without exhausting the performer.
- Anodised or painted finishes
- Combines with rubber edges for contact work
- Best for: stunt swords, long blades, broadswords
Resin, PU and rubber
Detailed, cheap to reproduce and completely safe to handle — the workhorse of convention-grade and rehearsal props.
- High detail from a single master
- Flexible or rigid grades
- Best for: cosplay, trainers, background weapons
Foam, latex and composite cores
Engineered to absorb impact and recover, with a core stiff enough to strike with and soft enough to be struck by.
- EVA, PE and latex skin constructions
- Fibreglass or carbon core options
- Best for: LARP, stage combat, youth products
Five checkpoints.
None of them optional.
Quality problems are almost always caught early or not at all. Our process is built so that nothing reaches the packing line unverified.
01
Incoming material inspection
Steel grade, hardness and dimensions verified against the specification before cutting starts.
02
Approved sample lock
Your signed-off prototype is sealed and kept on the line as the reference every unit is measured against.
03
In-line checks
Dimensional, weight and finish checks at every stage, recorded per batch so a fault is traceable.
04
Pre-shipment inspection
Cosmetic inspection of every unit, AQL sampling on dimensions and function, and photographs sent to you.
05
Packing validation
Drop and compression testing on export cartons, so what arrives is what left the workshop.
QC image · 3:4 · replace assets/img/qc-lab.jpg
The paperwork
your market asks for.
Testing is carried out by accredited third-party laboratories. Tell us the destination country and the intended user, and we will confirm what applies to your product at quotation stage.
Product safety
- EN 71 (EU toy safety)
- CPSIA and ASTM F963 (US)
- Age grading and warning labels
- Impact and drop test reports
Materials & environment
- REACH and RoHS declarations
- Material composition statements
- Nickel release testing
- Phthalate and heavy-metal screening
Trade documents
- Commercial invoice and packing list
- Certificates of origin (incl. Form A / FTA)
- HS code guidance and classification
- Product photography and measurement reports
About certification claims
Certificates are issued per product, per material and per market — a test report for one blade does not cover another. We will always tell you which documents exist for the exact item you are ordering rather than applying a general claim to everything we make.
Built for repeat volume.
Figures below describe the workshop as it stands today. We will share a live production schedule and current free capacity when you enquire.
4,000 m²Covered production and assembly area
60,000Pieces monthly capacity across all lines
4 linesMetal, polymer, foam and wood lines
Principal equipment
- CNC machining centres — 5 units
- Waterjet and laser cutters — 3 units
- 200-tonne hydraulic press
- Lost-wax casting and resin moulding lines
- Nickel, chrome, brass and zinc plating lines
- Powder coating and spray booths
- Fibre laser engravers — 6 units
- Woodworking shop and leather stitching room
How your order is managed
- One named account manager from enquiry to delivery
- Written production schedule with milestone dates
- Photo and video updates at sample, first-off and pre-shipment
- Approved-sample lock kept for the life of the order
- Spare parts and replacement policy agreed up front
- Preferred-freight quotes held for 30 days
Tell us what you need built.
Send a drawing, a reference or a sample and we will confirm feasibility, tooling cost and lead time — usually within 24 hours.