SOMEONE MAKE ZERO'S SWORD!

Because it IS a lightsaber.

It doesn't look round because it flares at the base, unlike Star Wars equivalents. If viewed in 3 dimensions, the flare still exists, but the energy blade would not be flat and planar like steel swords are. It's just a projection of plasma which doesn't hold a shape. It's more akin to fire coming out of a torch.

Also, steel can undergo controllable oxidation to reach several colors. Straw-yellow, light blue, blue, purple, and black. This is surface oxidation, and will wear with use.
Only other way is to paint it. No matter how good the paint is, it will ALSO wear with use. There's no such thing as permanent coloration when it comes to a cutting blade.

Why not just make one yourself? Make the handle, attach a cutout blade of clear Lexan or something, and use colored LED's to light it up.

Either way, it's not something you're going to cut with.

Personally, I prefer Zero's design in the Megaman Zero games. I mean, sure, he got nerfed, blown up a few times, and whatnot, but he still looks cooler in Megaman Zero, in my opinion. His sword's changed from a lightsaber to... well, a triangular lightsaber:

which would probably be easier to make if you were to do whatever steckfretman said about cutting clear plastic or something.
I probably wouldn't wear it, but having a functional suit of armor made to look like Zero's armor would be pretty sweet. And incredibly nerdy.

And I... *gasp* ...discussed it?

I gave you a few valid options. No reason to get all butt-hurt...

The design itself isn't all that complex. The hilt could be lathed from Aluminum and the blade cut from Lexan as I said before. It would take a little ingenuity, but it can be done.


There's no toy replicas because it isn't popular enough a character (or series, really) so as to make for a market strong enough to validate production.

And there's no functional replicas because when people try attaching steel blades to lightsaber-esque hilts, you get the "Samurai 3000" garbage which looks utterly ridiculous.

Another option is living with the plain, old straight beam, and getting a custom lightsabre hilt from one of the companies that makes them. I forget who does off the top of my head, but they're out there. The colored, light-up, "blade" tubes attach and supposedly are pretty strong.

It doesn't have the base-flare and raw energy shape, but it's the best you're gonna do without shelling out considerably more dollars.