Ive been seeing a lot of tech advances specifically using higher density foam to "extend" from the core with a similar strength to it.
My question is this, at what density (or specific construction method) can polyurethane be used as a core without a solid rod running down the middle? Given an axe handle design for the weapon (few inches thick in the loaded direction) would you need to pad the denser foam for haft padding? How much flex or shearing issues could you expect from stronger foams?
Im planning on stopping by a few companies near me to get some test samples to explore this further, just wondering if anyone already has some experience to help me along.