Flew home from MCO I yesterday. My kid each had had Droid in a backpack and their lightsabers, in their sheath. Droid went underneath the seat in front of them and the lightsabers in the overhead bin. No problems for either.
For our flight to MCO from home the TSA agent (manager on call) came very close to not letting me through security with my lightsaber. This was probably my 4th time taking it back to WDW. She was very clear that they do not allow weapons and then compared it to a lacrosse stick and said they don't alow those either. I explained that I flew home with it from MCO with no issue. She said, "they probably made an exception for you".