All of this still works around the issue of a stress point at the end of the rod where suddenly there is a dead end with little holding the end of the rod to the layer of foam just a round centimetre. This creates shear forces much like how scissors work. One layer goes up the other down.
What was needed was a way to see the rod gradually bending / finishing in a manner that is soft to the person being jabbed and that springs back to shape, or more simply make the end of the rod stiff but bendy and elastic. This way the rod does not pierce through the foam pulled thin over the tip.
The solution here was to attach a spring to the end of the rod.
The problem then is that springs being wire, do not have much to stick to the foam being hollow. Filling the spring with something solid defeats the purpose of the spring. Filling the spring with segments, some flexible filler and glue such as that used on neoprene foam wet suits, in between the spring rings stretches and bends the rod whilst maintaining a flexible outer skin. This enables adhesion between the solid shaft, flexible rod tip and foam layers granting a stiff blade but flexible compressible tip that does not stress the tip.
The only thing to do next was to throw in all the other features such as the plates and reinforced material cover to get super tough, reinforced springy flexible tips, ideal for jabbing an opponent without damaging them or the blade tip.