I made a blood sword for a client and wound up buying material enough for 2. It was incredibly easy however you absolutely need a saw (I used a jig saw) and a power sander (I used an angle grinder and orbital). Acrylic is incredibly hard and as such needs some heavy duty stuff to cut and shape.
Here's the art I used.
First step is to cut out the shape in the acrylic.
Glue them together (using special acrylic glue).
Grind down the edges.
Buff and sand until it is clear again.
Each sword takes me 3-4 hours even though there are only a few pictures. It takes light very strangely and photographs strangely as well. I shipped one off to the client and the other...well it was given away haha.