If you sacrifice just 1, then Dorn keeps his Blackguard powers and the sword is created with so-so powers. If you sacrifice both he looses his powers and becomes Fallen, but the sword is quite a bit better, of course he's freed from his bond and gets his free will back. Obviously he's a lot less potent w/o BG powers, so it may depend on whether or not you plan to keep him in the party for the long term. Possible option is to replace him in ToB with Sarevok.
And if you sacrifice the new demon and tell his old patron what was they tried to do, he gets a unique magic helmet as well as the sword and keeping his powers.
Depends on how the op wants to play. Sticking with the original patron is the best choice from a powergaming perspective, but if the op does rp runs, any option is open.
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