After having started with a fully 3D printed (except the core) parrying dagger as a very first experiment https://www.printables.com/model/246992-3d-printed-larp-safe-parrying-dagger
A longsword with a 3d printed cross guard and pommel https://www.reddit.com/r/LARP/comments/1cqaodj/made_a_new_sword_based_on_a_real_broadsword/
a bunch of stab safe rondel daggers (fully 3d printed, flexible core included) https://www.printables.com/model/529727-stab-safe-printable-larp-rondel-dagger
I now took it a step further and went for a design that is more or less impossible to make with the normal Larp weapon construction methods. A sidesword, with realistic thickness and proportions.
I already knew the material and its limits from earlier projects, but designing this one wasn't easy. Finding the right thickness, the correct good proportions to translate to Larp use. It took quite a bit of prototyping, but it is finished now. People who are familiar with real sideswords might notice that the space between the cross guard and side ring is actually too small to be able to curl your finger up above the cross guard. This is done on purpose since for Larp you aren't allowed to stab anyway. For all intents and purposes, this is a sabre, but with the flair of sidesword. I have a design that gives 1cm more clearance so you are actually able to curl your finger, but I choose not to make mine so wide. It has the looks, and that is sufficient.
I designed and made the cross guard and grip, but the blade and paint job was done by my friend from Falchion Creations. Foam smithing is not my speciality so I gladly let the expert handle that part.