The lightsaber is a carry on item. I made one (it was awesome) a few weeks ago and flew home on Spirit (slightly less awesome). There was no problem with TSA or security at all. It counts as a carry on item, though, as it has to be stowed in the overhead bin. On Spirit carry on items are extra so I just paid for that ahead of time. Orlando TSA had no problem dealing with it. I wonder what would happen if I wanted to fly BACK to Orlando with it... if one of my kids wanted to wear it into the park or something... I'm not sure how my home airport would handle that...