foam crafting

Now that you’ve gotten your foam, you need to know how to work with it. There is a variety of methods used to turn the sheets of HD foam into a prop or armor piece. How you approach it depends on your mindset and what you are more comfortable with. It also depends what you want your final results to be.

Some approach it as sculpture and gradually add or remove bits and pieces as they see necessary, others approach it similar to a sewing project where they create a pattern for each piece and slowly put them together. Some people approach it as an engineering project and build it from the ground up. Each person approaches it differently.

No matter how you look at your upcoming cosplay project you are going to need some basic tools. There is a wide variety of tools you can use, this is just a guideline to get you started, you will eventually find the tools and methods you prefer.

Cutter – You will need a sharp blade, in fact you will need several sharp blades. This is going to be one of your commonly used tools. Some like to use the standard box cutter, while others like a finer blade such as an X-Acto knife. You will also want several replacement blades so you can keep a nice clean edge on your cut.

Scissors are another very popular tool for foam cutting. You will want at least one heavy duty pair. Do not but the standard pair you would find in the school supply section. You want a large comfortable grip, the ability to open wide and nice sharp blades.

A common pair is the Fiskars Amplify Mixed Media Shears which are designed for heavy duty crafting. The heavy duty Slice Large Ceramic Scissors also work great for thick materials.

You will find that foam is hard on the your scissors. They will dull quickly and your edges will no longer be smooth. You could go buy a new pair of scissors, but I recommend that you simply sharpen them. This extends their life and ensure you continue to get a nice clean cut.

Fiskars has a good sharpener that is fairly inexpensive.

Fiskars Desktop Universal Scissors Sharpener

Stay tuned as we further explore other tools that you will need on your journey to cosplay crafting.

One of the most popular items to create a cosplay costume out of is EVA Foam. It is extremely versatile and easy to acquire. This material can be used to craft everything from accessories to complete suits of armor.

Robot by Laird of Cosplay is entirely EVA Foam

What is EVA Foam?

You are probably more familiar with it than you realize. It is commonly found in yoga mats, floor mats, and sports gear.

starro masks — Starro Masks made out of SKS EVA Foam by Laird of Cosplay

EVA (ethylene-vinyl acetate) foam is a firm, high-density foam that is softer and more rubbery than many of the standard polyethylene foams. It is also a known as a closed cell foam. EVA foam is responsive as it squishes when you press it and returns to its normal state almost instantly.

Why use EVA for Cosplay?

Most people start with EVA because it is durable, easy to acquire, and reasonably priced.
The solid, yet soft, material is easy to cut with basic tools such as scissors and box cutters (other favorite tools of cosplay crafters). It can also be easily formed with the application of heat.
It is lighweight and typically weighs about 2 lbs per cubic foot, which means that you can build an entire suit of armor without being weighted down.
EVA foam is UV resistant and will not break down or discolor when exposed to light. Many materials break down after prolonged exposure and start to discolor.

Where can I get EVA Foam?

Ideally, you want to go with SKS foam. It has a nice density, is easy to work worth, has clean edges, and comes in a variety of thicknesses. It is also a nice, light neutral color, which makes finishing your project a lot easier.

SKS Foam comes in a variety of thicknesses

If you are a first-time crafter, you might want to start with the cheaper option.

Puzzle Piece Floor Mats are a cheaper alternative

You’ve probably seen packages of them at your local stores. They are marketed as floor padding for garages, playrooms or exercise mats. These are (typically) EVA foam. This is a lower grade foam than the SKS mentioned above, but it is easy to find and you can start working with it now.

The problems with this foam are:

It is typically about 1/2″ thick, which makes it harder to work with and can lead to bulky builds.
It has a diamond pattern on at least one side.
It is darker colored, making it harder to achieve your final desired color.
They are cheaply manufactured, so there is no guarantee on quality or consistency.
If you buy the colored ones typically marketed for playrooms, they will frequently have a plasticy type layer.

[Cosplay 101] Foam Crafting – Cutting Tools

[Cosplay 101] EVA Foam Basics

What is EVA Foam?

Why use EVA for Cosplay?

Where can I get EVA Foam?