It is a bit of a stretch, but these are like frisbees and you can toss them and they fly pretty well indoors. It is impossible to hurt someone with it, it is soft foam.
You could source disks of foam from a local foam store (I actually have one down the street) and then rig up a hot-wire to cut out the bottom. I imagine you'd determine the curvature of the "radius" from the center to lip, then somehow find a way to keep the form while connecting a wire of some sort to a battery to generate enough heat for it to melt through the foam. I've seen them use a machine like this on a home decoration show, to cut out shapes and forms for pillows and stuff.
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