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How To Make A Simple Foam Pouch For Your Next Cosplay

Want to make a pouch out of foam? Then check out this guide!

Difficulty Easy

Time Less than 10 hours

Budget Less than $50

How To Make a Foam Pouch
Images Courtesy Maker Fishmeal

What cosplay is complete without a pocket or a pouch? I patterned my own small belt bags and absolutely adore them - I’ve made them in several colors and I take them from costume to costume. Since they’re so easily customizable, I have one perfectly sized for my cell phone, another for my business cards, and a third for my emergency super glue. The con necessities!

How To Make a Foam Pouch
Brigitte and Mandalytherin photographed by Munchkin Photos

Want your own? Here's how you make them: ⁠

Step 1. To pattern the front and back of the pouch, draw rectangles around the items you want to tote. Then add a little extra space to account for the thickness of the foam!

How To Make a Foam Pouch

Step 2. Create the pattern for the side wall by placing your item on its side next to the base pouch pattern and drawing a rectangle around it. Then cut out your pattern pieces.⁠

How To Make a Foam Pouch

Step 3. To pattern the bottom of the pouch, touch the corners of the front and side pattern pieces. Draw the resulting rectangle, then shorten it a bit to account for the foam thickness.

How To Make a Foam Pouch

Step 4. At this point the base of your pouch is now fully patterned. Take a moment to carefully label it, making sure to include foam thickness and number of pieces to cut. This is a pattern you can use over and over!

How To Make a Foam Pouch

Step 5. Transfer your pattern to foam and cut out the pieces.⁠ 2mm/craft foam works, but I recommend something a little thicker and sturdier. I use 6mm foam for my larger pouches and 3mm for the smaller ones.

How To Make a Foam Pouch

Step 6. For the front of the larger cell phone pouch, make a cut to allow for easier access.⁠ Otherwise, the pouch is too deep and narrow to grab your phone.

How To Make a Foam Pouch

Step 7. Using contact cement, attach the bottom piece to the back piece and the side pieces to both...⁠

How To Make a Foam Pouch

Step 8. ...and finally - attach the front!⁠

How To Make a Foam Pouch

Step 9. Pattern the remaining pieces! The flaps should be slightly wider and shorter than the fronts and each belt loop is a 1” by 3” rectangle.⁠ (Of course this is an opportunity for customization, if you want your pouches to attach by some method other than a belt loop or want your flaps to be more fancy.)

How To Make a Foam Pouch

Step 10. Transfer your flap and loop patterns to foam. I use 2mm foam for my flaps and 3mm foam for my belt loops. After a quick cleanup dremel (and possibly some googly eyes) you can complete construction!⁠

How To Make a Foam Pouch

Step 11. Now it’s time for your regular foamsmithing process! Heat seal, plastidip, and paint. The paint will highly depend on your costume - I have a “leather” set and a “metal” set that I switch between depending on the aesthetic of my cosplay.

How To Make a Foam Pouch

Step 12. To finish the project, add closures of your choice between the body and the flap. I like to use either velcro or purse snaps, but this is another opportunity for customization.

How To Make a Foam Pouch

Step 13. Modify to your heart’s content - YOU DID IT!⁠

How To Make a Foam Pouch

I love wearing these on the belt or even hidden under cloaks and armor. They add a huge peace of mind during long and busy con or shoot days, and I just adore customizing them based on the costume. Best of luck making your own set!

About the Author

Maker Fishmeal avatar

Maker Fishmeal

Contributor

Maker Fishmeal is an award-winning foamsmith, sewist, and propmaker with a primary focus on craftsmanship. Her goal with every costume is to learn something new and to turn that knowledge into guides for the community through tutorials and work-in-progress explanations. Fishmeal loves competing and builds one big competition costume per year. Her notable accomplishments include finalist for Riot Games Summer Finals Contest, published by Entertainment Weekly and Marvel Becoming, and Best in Show at Indy Pop Con and Cleveland ConCoction in 2019 and Origins Game Fair in 2018. Fishmeal lives in Ohio with her husband, cats, horse, and school of fancy guppies.

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