Foamsmithing 101: Choosing The Right Foam For Your Project
Having trouble figuring out which foam to use for your next cosplay? Look no further!
Armor creation for cosplay has cemented itself as a big player in costuming -- so much so that it is largely separated in competition as its own category and with its own judging criteria.
When cosplayers deem a costume in need of armor or prop pieces, the first step is to decide which pieces require which materials. In armorsmithing, the materials tend to be varied, but one of the mediums of choice that has come out as a fan favorite in cosplay is EVA foam (ethylene-vinyl acetate copolymer foam) due to its cost, ease of use, and lightweight properties.
Now that the basics are out of the way, let’s dive into some of the more known types of EVA foam (and maybe some lesser-known types!) and which ones will work best for your costume or prop.
1. Yoga Mats:
2. Foam Floor Mats:
3. Craft Foam:
4. Cosplay EVA Foam:
a. EVA 38 Foam: Foamsmiths tend to choose this type of foam for most armor creation, as it has a great combination of flexibility, durability, and cost efficiency. A favored thickness for most armor is between 4mm-6mm with thinner rolls used in detail work and thicker rolls for chunkier props, panels, and details.
b. EVA 60 Foam: Looking to make an amazing sword or prop? This is a great option as the density is higher and thus results in a stiffer, more solid prop that may allow for less internal structure. Higher density means that this foam will also take more heat to heatshape it, but it does hold its shape very nicely once finished. Cutting higher density foams makes for sharper, easier cutting and carving, and you can even use harsher tools like a belt sander for these without tearing it to shreds. Higher density is a little pricier, but very useful for creating props.
5. Plastazote:
6. Foam Clay:
7. Bevels and Dowels:
There are a multitude of other types of foams on the market today, but these basics are ones that can typically be found across the globe in some form or fashion and are used regularly in the cosplay circuit. If you’re unsure of which to use, many companies offer free samples to test them out! Happy foamsmithing!