Exploring the use of foam weapons being used in theatre as a safer practice. I crafted a custom made hilt from wood, wrapped in a latex texture made from a scrap piece of plaster that I Dremeled the pattern in to, resembling that of sting ray skin for authenticity to a samurai sword. A two part silicone mould was then made from this hilt, to be casted out of a high dense expanding foam. The swords themselves were cut out of a high density plastazote, two pieces were cut and a fibreglass rod was sandwiched between the foam to absorb the shock impact of the weapon, the swords were then sanded down to shape with part of the rod sticking out of the base of the blade. Finally the mould was coated with thickened latex and sealled up ready for casting. The blade was inserted to the top of the mould and lined up to sit straight and in the center of the mould, and the foam was poured in. I allowed it to sit for twelve hours to ensure the cast was fully dry, before removing and painting the weapon.