I made this full size Gladius sword in Sketchup using my imagination and a couple of pictures of Swords from the Roman Empire. Should be somewhat correct in size but I've never actually checked what size they should be.
The whole sword fits on one Replicator 2 printbed.
I've separated the sword into smaller pieces with interlocking parts for easy printing.
Glue all the parts together with strong epoxy and finish with some sand paper and a paint job of your choice. Good luck!