I believe that the Calimacil weapons were mentioned earlier, but their website
http://www.calimacil.com/technique.htm explains what makes their weapons different, going into some very explicit detail.
Long story short, the blades have no covering, either latex, cloth, duct tape, or other. The blade IS the foam. You'll also notice that all of their sword tips are blunted, and that the "cutting edge" is actually flat, instead of coming to a point. Here's a fun little video:
http://www.youtube.com/watch?v=6uAFLC7KjiY
I am very curious about these Canadian-made weapons, but I have yet to meet anyone that has one.
In related news, I've recently begun experimenting with making flat-bladed weapons that conform to Alliance/Nero standards, as I am actually an International player. I held off on this project until I was re-inspired by Dan Simmons weapons, shown on the Int'l boards
http://www.nerolarp.com/forum/showthread.php?t=662 . I asked him some questions, and he was very helpful, even sending me to the same instructions page that I was already using as a base model.
http://home.clara.net/arianrhod/Aldebaran/DoItYourself/ . The idea is simply to use this as a base design for making the blade, but insure the minimal foam thickness, include proper thrusting tips, and cover with duct tape as per standard.
Basically, he used steps 4-6, except that he strongly suggests keeping the "cutting edge" a minimal of 7/8" thickness. I ended up trying 1/2" striking surface for these edges. Oh, and instead of using the liquid cement in the instructions, I took Dan's suggestion of a spray foam adhesive, found at Ace Hardware, which worked very well. For shaping the blade, I actually ditched the proven utility knife for a hot-wire foam cutting board from Hobby Lobby.
Unfortunately, I found that with my Wal-Mart camp pad, and 1/2" striking edge, it felt too firm when struck by it. I'm about to order some polyethylene foam sheets (The same material as the walmart camp pads AND our pvc pipe insulation foam) from
http://www.foamandupholstery.com/polyethylene_foam.htm , and try again.
One of the issues here, and I think this is important, is that the current boffer-style construction method is easily taught and repeatable. The materials are inexpensive, common, easy to regulate, and simple to test for safety. Some people keep latching on to ONE aspect of boffer/latex weapon design, talk themselves breathless attacking/defending it, and then think that it proves their argument or disproves someone else's. In reality, it's the whole package deal that keeps boffers agreeable to our style of game.
Look, it's already hard enough to get into LARP. Once you get past certain stigma's or social hang-ups about larping, you then need to deal with the amount of
time,
money, and physical/mental
energy that needs to be invested. Boffers keep it simple. Boffers keep it cheap. They keep the game accessible to students or anyone on a budget, and because anyone can make them, everyone can build them to represent their character. Plus, I can STAB with boffers, which is something of big deal to me. After all, if you can't STAB with your larp SWORD, then that weapon simply isn't worth it in my book.
My ultimate goal to design a construction method for flat-bladed boffers that's easily repeatable by anyone, without crazy chemicals (As with some latex weapons), highfalutin' tools/machinery, or a serious increase in time or money investment. A method that, if we included in the rulebook, wouldn't make a prospective player exclaim, "You want me to do WHAT?? With my skills/finances?!?!"
Sorry for the length, this tends to be how all my posts go.