Foam Project Gallery

Here are just few of many creations from the past years!
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Why EVA foam?

EVA foam is an incredibly versatile and accessible material, making it ideal for a wide range of cosplay projects. Its lightweight nature and ease of use allow crafters of all skill levels to create detailed armour, props, and accessories. With just a few tools and some creativity, you can bring your favourite characters to life!

Lightweight

Comfortable for long wear at conventions.

Easy to Cut

Simple tools like scissors or craft knives work well.

Affordable

Budget-friendly for hobbyists and professionals alike.

Flexible

Can be heat-formed to fit various shapes and sizes.

EVA foam crafting steps

This guide will walk you through each step when crafting with my DIY printable patterns.

1. MEASURE AND CHECK SCALE
Measure your head circumference and make sure to check the scaling chart if 100% printing scale will be right for your head. If necessary, adjust the scale and print all pages.
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2. PRINT, TRIM AND TAPE
Print all pages on A4/US letter paper, and if you are increasing the printing scale above 100%, you might need to use the ‘Poster Print’ feature in Acrobat Reader. Once printed, all pattern pages need to be trimmed along the dashed lines with scissors symbols and taped together.
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3. CUT PATTERNS
Only once all pages have been trimmed and taped can you start cutting out all individual patterns along the outline stroke. Using a pattern notcher, add registration markers to help you later with correct parts alignment.
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4. TRANSFER, FLIP OVER AND TRANSFER AGAIN
All patterns need to be traced to foam, some (with double numbers i.e 1,1’) need to be transferred twice: as left and right hand side. Simply flip the pattern over to the blank side and transfer again. Check the ‘Part checklist’ to keep track of all elements required.
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5. CORRECT CUTTING ANGLE
Most parts need to be cut with a straight 90-degree angle; the blade needs to be positioned perpendicular to the foam surface. There are a few edges that require a specific inner or outer bevel edge, so make sure to look for the bevel edge symbol with the angle value and refer to the cutting angle chart.
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6. GLUE - FOLLOW THE ASSEMBLY ORDER
Once all parts have been tested to see how they all fit and you have familiarized yourself with the assembly steps, it’s always better to work in small steps and not try to glue everything at once. Patience (and correct alignment) is the key to a great-looking build.
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7. HEAT SHAPE
Once the helmet is ready, allow the glue some time to set before proceeding to heat shaping. To improve the overall helmet geometry and shaping, you can use a heat gun and bend the foam more to your liking.

8. BATTLE DAMAGE (Optional)
If you want to give your helmet a more realistic, battle-worn look, you can add some damage effects. Use a rotary tool to create scratches and dents, or use a wood-burning tool for deeper marks. Take your time to achieve a natural and random look.

9. SEALING SURFACE
Before painting, it’s important to seal the foam to create a smooth surface and protect it from absorbing too much paint. Apply a few coats of a sealing product like PlastiDip or a similar flexible coating, allowing each coat to dry completely.

10. PRIMING AND PAINTING
With the surface sealed, you can now prime your helmet. Use a primer suitable for EVA foam, applying an even coat and letting it dry fully. After priming, paint your helmet with your desired colors, using multiple thin coats to achieve the best results. Finish with a clear coat to protect your paint job.

11. WEATHERING
To give your helmet a more realistic and aged look, you can add weathering effects after painting. Use techniques like dry brushing to highlight edges and raised areas with a lighter color, and apply washes to bring out details and create a worn appearance. You can also add small specks of dirt and grime using a sponge or toothbrush. Allow the weathering to dry completely before moving on to the clear coat.

Materials & tools

Here is a short list of absolute-must to get you started!

EVA FOAM:
You will need a wide range of various thickness and density. Best if you check your local craft store. Another great source of the material is eBay and Amazon. You can always order online from a cosplay craft store like www.poly-props.com

Most of this items can be easily sourced online (Ebay, Amazon, craft stores), but you can also check your local B&Q, DIY, hardware or art shop to see what they have in stock. This list is not complete and there are multiple other products that can help you with the project at various stages.