One of our members Matsuo made a "Sword of Kahless" version, a mek'leth, as well as a Daqtagh for me ahwile back. They're all AWESOME. I don't know if he's still making them, but frop him a line, you never know.
I drew a full size (48 inch long) Bat'leth long ago with the intention of making one out of sheet aluminum. I never got around to it. If someone want to use the pattern please go ahead. All I ask is that you send me a pic of the finished product.
I've since lost the original graphic file but the above jpeg file should provide a head start. All you need to do is to get it traced in AI or other graphic software a laser cutting company can use, and get the whole thing laser cut out of 8mm sheet aluminum, or MDF board.
After that its just a matter of filing the blade edges to a razor sharp edge, or make it blunt so you don't decapitate someone. Wrap some leather strips for handles and you're done.