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Over the years I've thought a lot about how to make boffers. I came up with a crude system to put different creation styles into different classes. The way I think of weapon construction goes like:

First generation:
This is the start of weapon theory. It's doesn't have to be the crudest or lowest quality of weapon, but it's the easiest style to learn. This style is typically PVC cores with pipe insulation over that. The outer layer is covered with duct tape and the thrusting tips are usually wide and thick.

Second generation:
This style is a progression of the need for weapons that are easier to control and swing faster. I usually think of weapons in this class as having bamboo and fibreglass cores. The striking surface varies between pipe insulation and flatblade designs. The outer layer is usually constructed from a fabric cover. Fabric is lighter, easier to remove for repairs, and holds up to damage better.

Third generation:
This is where folk start to push the limit of what off-the-shelf components can do. Experimentation is done to make ultra-light weapons and really crank out swords that swing fast as lightning. Cores are usually graphite, foam use becomes a varied composite.

I think the durability and the look are most important on a weapon. It's on the player to wield it realistically.

no need to tell me i know it's hard work. i've done it myself

I wouldn't call it move... they just start in that phase right away