Here's a simple way to make cheap, fake metal props that will not easily bend and crease. I had heard styrene sheets were a good material for costume armor and weapons, so I thought I'd give it a try.
This is a method commonly used by cosplay costumers. Most of my research brought me to Amethyst Angel's tutorials
, which go into greater detail for more specific and complex prop builds. Here I simply cover some of the basics of this technique.