Conventions are the whole point. You put all this work (and money) into a prop, and the payoff is carrying it through a hall full of people who are going to lose their minds when they see it. But getting there with your prop intact — especially if you're flying, or driving long distances — takes some planning. Here's what actually works.
Domestic Flights: Checked Luggage is Your Friend
The single most important rule of flying with cosplay props: check them as luggage, don't try to carry them on. TSA has discretion over what gets stopped at security, and a large sword (even obviously plastic) creates unnecessary stress for everyone. Most props can be broken down, padded, and checked safely — and with checked bags, you have a lot more room to work with.
Packing Your Prop for Air Travel
- For swords and long weapons: A hard-sided golf bag or ski bag works beautifully. Golf bags are designed to handle long, rigid items and are accepted as standard checked luggage by most airlines. Line the inside with bubble wrap and make sure the prop can't shift.
- For helmets and armor: A hard-sided suitcase (not soft) with foam padding cut to cradle each piece. Pack clothing around and between pieces to absorb vibration. Don't stack heavy pieces directly on top of painted surfaces.
- Label everything: Put your name and contact number inside the bag and on the outside tag. Convention centers and airports do reunite people with lost luggage — but only if it's labeled.
Airline Size and Weight Rules
Standard checked bag limits are usually 50lbs / 23kg and 62 linear inches (length + width + height). Our full armor suits typically check in well under 50lbs even with packing materials. The elemental staffs from Black Ops II are the longest props we make — these will need to go in an oversized bag or golf bag. Check your specific airline's oversized baggage policy before you book.
Road Trips: Easier Than Flying, But Still Needs Planning
Driving gives you a lot more flexibility. You can bring more, you have easier access to your props, and you don't have to worry about airline rules. But there are still things to watch out for:
- Don't leave props in a hot car: This bears repeating. A summer car can reach temperatures that will warp or soften PLA props. Always take props inside with you at hotel stops.
- Use the trunk: Not the back seat. A sword sliding around in the back of an SUV at 75mph is a recipe for damage. The trunk, with props lying flat and padded, is much safer.
- Bring repair supplies: A small kit with super glue, a mini bottle of clear coat, and matching touch-up paint takes up almost no space and can save a prop that gets dinged on the journey.
At the Convention
Most major conventions have prop policies and weapon check procedures. Here's what to expect and how to handle it:
- Prop check: Many conventions require you to have props peace-bonded at the door — this usually means a zip tie or ribbon attached to a weapon to show it's been inspected. Find the prop check desk as soon as you arrive; it's usually near the registration area.
- Rules about length: Some conventions have maximum prop length rules. Check the convention's policies on their website before you travel — typically anything under 150cm is allowed, but this varies.
- Photography breaks: Plan to set your prop down during long panel sessions. Holding a 1.5kg greatsword for three hours is exhausting. Know where your room or bag is so you can drop it safely.
International Travel
We ship worldwide, and many of our international customers travel between countries for conventions too. The same principles apply as domestic flight travel, but with an extra consideration: customs. A clearly labeled package (or suitcase contents) describing the items as "costume props, no commercial value" helps prevent delays. Keeping your purchase receipt accessible is also useful if questions arise at customs.
Have questions about a specific prop for an upcoming trip? Get in touch — we're always happy to advise on packing for your specific pieces.
