So, considering how hefty this replica is, and considering how accurate in weight it probably is to the original, would it be safe to assume that the metal hero was barely used because of that (and probably other factors)?
Aside from one specific promo picture, the visual dictionary and the famous shot of the hilt before it is kicked by Darth Maul, I struggle to find any evidence of it being actually used on screen on Ewan McGregor's belt.
In almost all cases he is wearing the resin belt hanger (with metal emitter?) which is easy to spot with the all-black grip section.
Of course, the OT used found-part metal props. You can see onscreen just how heavy the Obi-Wan ANH saber was as it hung from Guinness’ belt, as well as Hamill using his hand to steady the Graflex so it wouldn’t smack him in the leg (or crotch) during scenes where he had to run.
For TPM, they made the metal heroes, but the painted resin versions were obviously very practical for the actors’ comfort. And, for the next two films, they made the leap to chrome-plated resin props, which did the job of perfectly simulating metal props onscreen while also being convenient and lightweight.
Come to think of it, I find myself wondering if creating the AOTC version was less of a necessity (because the TPM hero was lost or in private hands) and more of just simply using the same methodology for the sake of consistency (lightweight, chromed resin props), as was employed for the that film’s new saber designs (Anakin, Mace, Dooku).
Surely, there were leftover, painted-resin TPM sabers to reuse, but they specifically created chromed versions for AOTC.
Also, I have the sneaking feeling that some people bash the AOTC version simply because of the VISUAL DICTIONARY photo, which actually looks to be a stunt version, rather than a belt-hanger.
After all, the prop featured in the closeup photo looks rough, with a paint-chipped red button, and what appear to be silver-painted grip-grooves…
…while the belt-hanger seen on the opposite page appears much more pristine, and also with properly-chromed grooves.