After looking at what was available in terms of padded weaponry, I made my own. I used schedule 40 PVC wrapped in insulating foam. I made a vinyl sleeve for the unit that looks very professional. It ties at the bottom. The handle is wrapped in the same stuff used on tennis racquets. The cost was less than $10 and works well.

I have tested them fairly extensively. Nobody has been hurt even though nobody has worn any armor while using them. I learned early on to leave a couple of inches at the tip unsupported by PVC. This allows you to thrust without hurting anyone. I also fill that last couple of inches with additional padding. The insulation padding is glued to the PVC to keep it from flying off during forceful strikes. I have considered adding a guard, but haven't found the need yet.

Let me know if you are interested and need more information.

Very respectfully,
David W. Johnson