Disclosed are methods of making polymeric swords and sparring instruments having improved mechanical properties. In one embodiment, a method of making a polymeric sword includes centering a flexible support member on either a first half of a sword mold or on a second half of the sword mold; pouring a polymer mixture into the first half the sword mold and into the second half of the sword mold and closing the sword mold by clasping the first half of the sword mold to the second half of the sword mold; heating the sword mold comprising the polymer mixture in a heating apparatus; and removing the polymeric sword from the sword mold.