DD purchased the double lightsaber and just took it apart and put it in her build a bear box. She's become quite the pro at assembling/reassembling it.
My brother flies from SFO to MCO on United Airlines to participate in Star Wars Weekends with his Storm Trooper armor (costume) and movie prop/not real/non-functional 'weapon' packed in a box to be baggage checked (not carried on).
At the ticket check-in counter, he has to remove the movie prop 'weapon' from its travel box. They inspect it, and then it gets re-packaged up and baggage-checked. At some point along the route from SFO to MCO, the box is opened again and the TSA puts that (familiar to many travelers) notice inside stating that they inspected the box.
So, I guess if the items are clearly toys, there is no need to declare them. If they are not clearly toys, then a pre-bag check inspection may ensue (just as it does if one is checking a real fire arm).
Lucky kids... I want a light saber! Have a great trip!
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