Boffo swords are a common sight at various kinds of faires. The version I make is I think safer than some of the other designs, especially with smaller children. Heavy handed blows with this one don't hurt anywhere near as much as the ones with pvc or other more solid cores.

For the event this photo came from, we also modified some baseball masks to provide some additional protection, mainly for the smaller children. Most adults will be fine without a helmet, and in fact I've had my glasses knocked off several times and have had to stop and search for a popped out lens one time.

These will break if used too hard, which is fine. The idea is a test of skill and agility, not strength. If your fighters want to use "crowbar" style sword fighting in which size, strength and hard hitting are more important than skill or agility, then a solid oak, locust or even steel core should be used. And probably full armor should be worn.

Even so, always check them before use. Make sure the handle is still firm and in place and that a gentle bend of the "blade" doesn't reveal internal breakage. Run your hands over it to make sure any bumps are not serious. If one breaks during use, stop and replace it.

Noodle Sword making (30.4.1)

Tools and supplies to make noodle swords
A knife is the only essential tool. I use the tape measure to keep them the same size, and the home made tape dispenser makes the taping job go smoothly. A swimming noodle, cut to the desired length, is the main body of the the sword. I use a bunch, 5 to 7, of tomato stakes so that the impact is not as bad as when something stiffer, such as pvc pipe or even golf club handles, is used. The plastic bags are stuffed in the "pointy" end so that there is a cushion between the ends of the tomato stakes and the end of the noodle. Assemeble and tape well.
Measure desired length and cut noodle.
A sharp knife is not essential, but a good idea.

Tape the ends of the tomato stakes
These will most likely need cutting so that all are the same length. If your knife is sharp enough you can use that, but pruning shears would work better.
At least an inch of hole will be filled with plastic bags.
The plastic holds better than cutting a piece off another noodle and stuffing it in here.
Stuff them tight.
It is important that the tomato stake bundle can't come out the end.

Tape the business end.
It will also be covered again in the whole sword taping process. Some extra here helps.
Tape the handle so it will stay in place.
Although I've tried various kinds of blue, in the end the usage of these is too rough for glue, but if there are enough vertical strips holding the handle in place, and well as some diagonally with one end on the noodle. it will last.

I prefer long ways taping.
Diagonal or other fancy patterns can be used. It is important that the surface be smooth so it won't have chunks of tape out there to catch on clothing or scratch skin.
the handle needs diagonal taping for strength.
Whatever taping pattern you use, you will want a smooth grip.