Staffs can be built that can perform properly, withstand heavy sparring with other weapons, and yet still be safe for unarmored contact. For sparring staffs, 3/4" schedule-40 PVC can be used by inserting another smaller diameter PVC pipe (larger than 1/4" but smaller than 3/4") inside,  then insert 1/4" wooden dowels into that. The core is then padded by rolling it up in 1 1/8" of Landau padding. Do not use pipe insulation foam for sparring shafts. Due to the unique requirements of staff weapons, using this method achieves a design that does not whip or bend and has a good weight and feel.

The core materials must be secure inside (not rattle) and the outer foam must be well glued and taped. On the last 6"-8" of the striking ends, attach an additional 1/4" of Landau padding foam as extra padding. Striking staffs also require cloth covering.