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 and we are going to give you a few of the EVA foam basics to start your cosplay crafting journey.
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.
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.
If you are a first-time crafter, you might want to start with the cheaper option.
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 Floor Mats
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 that you need to sand down if you want to hide the texture.
- 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.
Even the experienced professionals will still use these for the bigger blockier parts of the armor, or the invisible parts that are less likely to be seen as this a much more cost effective material.
Not Quite ready for the Expensive Stuff?
If you want to go to the next step in EVA foam, then many of the box stores also sell rolls of EVA foam in various thicknesses. These are not as good in quality as SKS Foam, but they are quicker and cheaper alternative.
What’s Next?
Ready to start cutting? Before you make your first mark, make sure your workbench is stocked with a few essentials.
- A sharp blade (or several)
- A self healing cutting mat
- A heat gun
- A bonding material such as hot glue or contact cement
- Your finisher such as a paint or sealant,
Now you can move on to the construction and bring your imagination to life.
To see what cosplay conventions are coming up
be sure to check out our Cosplay Convention List!
