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!! I had no idea it came up in searches at all....oh my gosh thank you so much for letting me know!!! ((and thank you!!! I just really love cosplay ><))
It isn't aluminum--it isn't even metal at all! It's just a cheap plastic bat like you'd use for kids or a costume. This is the one I ordered. I'm sure you could find other similar ones, though, especially if you need a specific size. What I did was sand down the seam in the plastic so it was totally smooth, spray paint it silver, and then wrap the handle in electrical tape. While I'd love to have an aluminum bat for him, you can't bring any weapons or props made of metal into conventions, so this is the safest option. Although a little bonus to spray painting it: as it gets beat up over the year, the black base shows through and looks like scuff marks. I didn't plan it but I like it anywho XD
Environmental considerations aside, lets consider kids plastic wiffle ball bats as something I think all Americans are familiar with https://www.amazon.com/WIFFLE-W100-Wiffle-Bat-Ball/dp/B0044FTK1C/ref=sr_1_9?keywords=wiffle+ball+bat&qid=1654273485&sr=8-9 For those outside the U.S., it is a cheap plastic baseball bat and ball for kids.
For the purposes of this arguement I'm making up numbers to prove a point.
Lets say that "Wiffle" can produce a bat and ball as is, for $10 or produce one with 50% more plastic for $11. Now Wiffle could produce that superior ball and bat, but will it help them sell any more bats and balls? Well, MOST consumers do not really use many of the products that they buy. Many of us grew up on Wal-Mart bikes. If you have bought one recently, they are complete crap and fall apart after 100 miles or so, but MOST consumers don't ride a bike 100 miles in their life. By producing a "Crap" product Wal-Mart is able to keep prices down, and those that use it more than that are in the minority and buy a better product.
Back to the wiffle ball bat. If Wiffle made better quality bats they would likely sell less of them because fewer would break and need to be replaced. Throwing some more made up math into this, if wiffle used 50% more plastic to produce a "tougher product", they would use 50% more plastic in manufacturing. If less than 50% of the original unstrenthened product was being thrown out due to breakage, wiffle would actually be using more plastic overall by designing things to last and not be thrown out.