The sword would be 3D modeled in fusion 360, using in game pictures of the sword. The guards/Pommel, and overlay would be 3D printed, while the Core spine of the sword would be laser cut from x2 layers of 6mm MDF.

A closer look at the detail in the fusion 360 model

A full picture of the assembled sword. The laser cut Blade has been shaped, and fiberglass has been laid over the core to add strength. 

My hand gripping the sword. To give a sense of scale

The Greatsword measures in at 175cm in length, compared to the 1.1 meter long single handed version of the same weapon from an earlier build

The scroll work on the guards had to be cut out with a rotary tool. A happy accident was that the porous filler material had a similar texture to the rough forged look from the reference material

The parts were primed with a white filler primer. 

After priming, the exposed metal parts were sprayed with a satin black. This would be followed up with a metallic silver. The un-painted portions would be covered with leather

The metallic silver portions ready for weathering. 

The full finished sword