prop master Kerry Van Lillienfeld tells Polygon the sword presented a huge challenge during pre-production, especially when they approached it like they would any other prop. His team first tried to make a “soft” version a pliable, lighter version made of foam and rubber in a 3D printer. The resulting model weighed “between 30 to 40 kg,” or around 66 to 88 pounds.
“I could hardly pick it up,” Van Lillienfeld says. “It’s soft, but it will crush you to death.”
The greatsword is one of Monster Hunter’s most iconic weapons. While it can take many forms, depending on which gigantic monster parts it’s crafted from, one of the most often referenced looks like a long, curving jaw bone, complete with oversized pointy teeth. That’s what Van Lillienfeld attempted to replicate, while also faithfully maintaining the outlandish scale to its wielder.