How the Sword-Making Workshop Works

Knights Larping Battle is planning future foam sword-making workshops where participants can design, shape, and decorate their own foam sword for battle.

To keep the workshop safe and organized, the main sword blank will already be prepared before the workshop begins.

Step 1: Prepared Sword Blank

Before the workshop, Knights Larping Battle will prepare the basic sword blank.

The foam pieces will already be attached together with a fiberglass rod safely secured inside the center. This gives each sword a strong inner structure while keeping the outside padded and foam-based.

Participants will start with a rectangular foam sword blank instead of building from loose materials.

Step 2: Choose a Sword Template

Participants will choose from available sword templates based on foam swords currently used at Knights Larping Battle.

Many of these template shapes are inspired by professionally made foam swords that have already been used, tested, and approved for safe play. This helps keep the workshop swords familiar, practical, and battle-ready while still allowing room for personal style.

Templates may include different blade shapes such as:

  • Classic sword

  • Long sword

  • Short sword

  • Fantasy-style sword

  • Simple beginner sword

Once a template is chosen, the shape will be traced onto the prepared foam blank.

Participants can customize colors and details, but the main sword shape must stay within safe workshop guidelines.

Step 3: Draw the Sword Shape

Participants will draw or trace the sword design onto the foam blank.

This is where they begin making the sword feel like their own. The design can be simple, bold, clean, or creative — as long as it stays within safe workshop limits.

Step 4: Cut the Foam Shape

The foam will then be cut into the chosen sword shape.

Cutting may be done with guidance or assistance depending on the participant’s age, comfort level, and safety needs.

Step 5: Shape and Sand the Sword

After the sword is cut, the edges and shape will be smoothed.

This may include:

  • Belt sanding for the main shape

  • Detail sanding for smaller areas

  • Smoothing rough edges

  • Rounding corners

  • Cleaning up the blade shape

All sanding will be supervised and handled carefully to keep the process safe and controlled.

Step 6: Paint and Decorate

Once the sword is shaped, participants can paint and decorate it.

This is where the sword gets its personality. Participants may add colors, designs, symbols, handle details, or team-style decoration.

Step 7: Final Safety Check

Before any homemade sword can be used in Knights Larping Battle, it must be checked for safety.

We will look for:

  • Safe padding

  • No exposed fiberglass rod

  • No sharp edges

  • Safe tip and handle areas

  • Controlled striking surfaces

  • No overly hard or unsafe spots

A sword may look awesome, but safety comes first. Only approved swords may be used during official matches, warm-ups, or open sparring.

Step 8: Bring It to Battle

Once approved, the sword can be brought to Knights Larping Battle events and used in approved battle formats.

All homemade swords may be rechecked later if they become damaged, worn down, or unsafe.

Cost

Estimated cost: $30 per sword

This helps cover prepared sword blanks, foam, fiberglass rods, glue, paint, supplies, tools, sanding equipment, and workshop setup.

Final cost may vary depending on materials and sword style.

Important Note

The workshop is designed to be creative, fun, and safety-focused. Participants will not be making real weapons. They will be shaping and decorating padded foam swords designed for safe foam combat.

Choose your shape. Build your style. Get it approved. Bring it to battle.