Design and Dimensions: The design of the khopesh sword, including the curvature of the blade, the shape of the hilt, and any decorative elements, should be determined. Dimensions such as overall length, blade length, and hilt length need to be specified.

Materials: Carbon steel is often chosen for its hardness and edge retention. The type of carbon steel, such as 1095, 5160, or others, can affect the sword's performance and appearance. The hilt (handle) can be made from materials like wood, leather, bone, or synthetic materials for grip and comfort.

Blade Construction: The blade's construction involves forging, shaping, and heat-treating the carbon steel. The heat treatment process is crucial for achieving the right balance of hardness and flexibility.