in fact if you know a little about ancient history, you would know that every culture has the traditional sword making method of folding the metal and useing high temp and adding different material to reinforce them, it's only due to the fact that wars were getting bigger that molds or other mass production are use to make them which would at the expense of the weapons durability would be produce at a higher and cheaper rate.

that's why swords and other bladed weapons for nobles and aristocrats emperors are way more expensive not just because of it's lavish decoration but mainly due to the fact that it wouldn't break when swords clashes.

and the only reason that Japanese katanas technology are slightly above that of other cultures is due to the fact that unlike other prize swords a katana is made out of 2 different alloy a hard outer edge and a more flexible metal use to reinforce the blade.

*cough* only 7 chapter out so far.

and yes he can make temporary swords of different elements

not all maken has human form

it has already been stated that aria and other maken that can transform into human form are special.

and maken are demons just in sword form.