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Cosplay is an awesome and fun hobby, though with expensive materials and tools it might me scary and discouraging for newcomers. While Worbla is a great solution to create armor and props with, I would like to talk this time about super affordable EVA foam. It’s cheap, easy to find and just as fun to work with!

You might have noticed that many of my costumes in the past where mostly just Worbla. I got a little bit bored though and switched to EVA foam, which gives me not only new challenges but also forces me to learn new techniques! For example, my Sole Survivor was my first full foam built and the first time I applied the rusting technique.

Photo by eosAndy

Photo by eosAndy

And here is the progress of my Gauss Rifle, which as you can see, it’s also out of foam!

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Check out our building video of the Gauss Rifle on Youtube. (Ignore the weird intro, it was totally Benni’s idea!)

I really like how the costume turned out! Plus: It cost me maybe $100 to $150 in total using only high quality EVA foam! My other costumes in comparison were a lot pricer and also less comfy to wear. So, if you’re searching for a good Worbla alternative to create your costume, let me introduce you to EVA foam!

In general, there are a million different kinds of EVA foam in various thicknesses, colors, densities and chemical compositions. The most well known is probably cheap puzzle foam mats, which you can easily find on Amazon. They are around 10mm thick, come in a puzzle shape of 60 x 60 cm (24 x 24 inches) and have a rough texture on one side. They are the cheapest version (6 mats for 23$), but will cost you more time and effort to built something (since you might have to get rid of the texture again).

My personal favorite is high density EVA foam, which you can get get from cosplayshop.be, a crafting shop in Belgium – they also ship the US btw. This material comes in 10, 5, and 2mm sheets, is smooth on both sides and is more durable compared to other EVA foams. It actually costs 60€/65$ for a sheet of 2m x 1m. That’s surely more price than the cheap floor mats, but the material already comes smooth on both sides and you have a minimum of waste material since you’ll get a single, very large sheet of foam.

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Depending on what you want to build, it also helps a lot to find a foam which actually shrinks by heating it up instead of simply melting. You can see why in the following picture. By cutting lines with a sharp blade and heating it up afterwards, the lines will widen. This is extra helpful for adding details on armor and props. Just order a sample and try this out, then you’re good to go for your upcoming material order! (P.S. If you have foam that melts, the cuts will disappear again when you heat it up!)

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Aside of high density EVA foam, you’ll also often find black mats, which are softer. They are called L200 in the US, Pro Foam S from Craftperium (a crafting shop in Germany) or EVA-PE45kg from cosplayshop.be, all pretty much the same products. This foam is cheaper and melts together under heat, though it’s easier to heat shape and more lightweight. Just the perfect materials for affordable armor costumes! It’s also the black foam you’ll see in the following pictures.

As you can guess, you will also need some glue to connect your foam pieces. Unlike Worbla doesn’t just stick when you heat it up, but needs a strong adhesive to stay in shape. A common solution is contact cement, contact glue, Kraftkleber in Germany or Barge (in the US). I’m using contact glue from cosplayshop.be, but Minque.nl also has a great glue called DuraCol.

Contact cement is basically a very strong adhesive which you have to apply in thin layers to both sides, let it dry properly and then press both parts together afterwards. Depending on the glue, drying might take a while longer. Mine dries actually instantly and allows me to work pretty fast. The bond created here might destroy your foam if you try to rip it apart, so work carefully and think about your next steps.

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Additionally you’ll need some tools to work with foam but nothing fancy: A box cutter and an exacto knife, a dremel and a heat gun. That’s pretty much all! And yes, even if you prefer to build your costumes and props as simple and cheap as possible, these are tools you have to get. They are pretty much the basic and I guarantee you, you’ll need them for all your upcoming projects as well.

So, wondering now to create an armor piece in general? Well, as always you’ll need a pattern first. I made one for a shoulder armor and adjusted the shape a bit. Afterwards I transferred the template on 10mm black EVA foam, cut it out with my box cutter and covered the edges with contact cement. Once the adhesive was dry enough, I simply pressed both edges together. For a little bit more depth I added an additional layer with a beveled edge and my shoulder was done! Super simple, right???

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Here is another shoulder piece – this time with a fancy paint job. As you can see, I used high density EVA foam here. Why? I simply had some laying around in my workshop. I applied a bumpy texture with some latex and texture paste, painted it black and rubbed it carefully with the wax paint Rub’n’Buff. The result looked just like metal, despite of being simply foam! You’ll find a more detailled tutorial in my latest Advanced Painting book!

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You’ll also find some helpful tips and trips regarding to priming. My current favorite is PlastiDip, which is a spray on rubber coming from the car industry. It’s actually toxic and flammable, so you’ll need good ventilation or have to spray outside. I actually built myself a handy spray booth out of an IKEA closet. Additionally you need some practice to get a clean application (Benni always messes this up!) and using this stuff for a whole armor set might be a bit pricy. A can only costs around 8$, but you’ll need around three layers so they do not last very long.

A cheap alternative is latex milk. It’s a natural product, can be brushed on and is completely non toxic. If you apply it with a brush, you might create little flakes in your priming coat so be careful. If you like to have a super smooth base for your paint job, latex probably isn’t the right solution for you unless you spray it on with a critter gun.

Something I really like is actually Flexbond, which seems to be a mix of latex and white glue. It’s works basically like simple white glue, though it dries out flexible. This means your paint won’t chip of anymore and you don’t need to worry about cracks in your armor. Clearly a good alternative if you don’t like latex or Plasti Dip. You’ll get Flexbond in Europe from cosplayshop.be and in the US and Canada from cosplaysupplies.com.

Oh, and this is an armor piece I made out of high density EVA foam and primed with Plasti Dip.

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If you want to get more into costume and prop making, check out my brand new Costume Making Guide, which introduces you to cosplay in general and shows you how to work with EVA foam AND Worbla. It teaches you all kinds of different techniques to shape, prime, and paint your costumes and props! It’s the first ‘official’ book I released with an US publisher, so I’m quite proud of it! You’ll get it in my shop or on Amazon!

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Well, back to the topic…

Another shoulder armor (everybody needs shoulders!). The shape is completely different, though the pattern is still super simple. I used my dremel to sand down the edges into the right angle and connected all pieces with contact cement. The “metal rods” were just PVC pipes wrapped with 2mm stripes of EVA foam. For an used and realistic look, I also added some battle damage with my dremel on top.

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And here is a little step by step guide of my D.Va gun from Overwatch. You can also download the blueprint here if you want to build it yourself! 🙂

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Do you want to learn more about EVA foam guns? I already wrote a book on this topic: Advanced Prop Making – Guns and Rifles.

And last but not least, here is an EVA foam breastplate from my still unfinished Nova costume from Heroes of the Storm.

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As you can see, it’s quite simple, but takes some patience and time. Planning a costume or prop ahead is always helpful as well. That’s why I always prepare patterns and Benni draws blueprints for me. EVA foam is a great material, though you don’t just snip with your fingers and your costume is done. Same goes for Worbla though. Both materials have their advantages and disadvantages, but I hope this posts shows you that some skill and time is enough to create something awesome even with a tight budget.

So, no need to worry! Instead get up and start crafting! 🙂

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