It should go without saying that you shouldn't attempt to bring any weapons aboard a flight, but the TSA finds thousands of improperly stored firearms every year. You must keep all firearms in locked hard-sided containers in your checked baggage. You also have to declare them to the airline.
These rules also apply to toy or replica weapons and firearms.
You don't want to get held up at TSA because you kept your cosplay katana in your carry-on. It is worth noting that replicas of explosives, like hand grenades or mines, are always prohibited in both carry-on and checked baggage.
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