If you’re planning to take any sort of prop to a convention, be sure to visit the convention’s website and read their costume policy. If you can’t find one, contact them through their site or social media because you don’t want to pour a ton of work into a prop only to arrive at the convention and be told to take it back to your vehicle or home. Safety restrictions meant a Harley Quinn cosplayer couldn’t carry a precise replica of the character’s wooden bat in Suicide Squad. Instead, she commissioned VFX Foam to make one for her from acceptable materials — which also works out because it likely made the bat lighter and easier to carry.
Customer opted to go with a foam bat due to strict convention rules about wooden bats/real weapons. We added a wood rod that runs down the center of the bat for structural rigidity and to give it a little weight. Wood-grain texture added by airbrush along with the graphics.