A basic introduction to Craft Foam

Craft foam is a popular material. It can be found easily in a number of arts and craft stores, is very cheap, lightweight, easy to use and comes in many colours. Many cosplayers use it at least once and it can be used to make simple accessories and armour. Although it might look like something that a small child would play with, when crafted right it can really bring jaw dropping results.

Pst! That does not look exciting at all!

Oh...my...God! (and this is just the basics!)

The stuff can be cut, painted, used to make patterns, glossed and even heated up to change shape. The possibilities are endless!

I have made several Sailor
Moon tiaras using this method! 

The only major downside I have found with Craft foam is that it requires some preparation if you plan to paint it. Being a porous, sponge like material, it would absorb whatever paint that touches it. The solution is simply apply several (usually more) layers of PVA glue (the type you played with back in your school days) that is watered down. About 2/3 water should do. If after applying several coats and the paint job still looks iffy then you can still always add more glue. I love adding more layers because it makes it so shiny shiny na no daaaa!!!!

Craft foam can be layered for added sturdiness but if you don’t what it to become too thick you can simply use some PVA glue to attach some fabric behind it. Should be nice and sturdy after a few coats. For my Sailor Jupiter tiara I have simply reinforced it with a layer of craft card onto the back as it can be quite flimsy without the support.

Scissors does the trick when you cut the Foam but for neater edges you may be better off using a cutting knife or scalpel.

One particularly neat thing about Craft foam is that it can be thermoformed. Although this term might sound intimidating it is actually rather simple and very handy technique to know. Like Worbla, it can be manipulated with a heat source, usually a heat gun, an oven stove or simply a hair dryer. Using my Justin (Grandia) armour for example, I have managed to keep it in shape by cutting the foam into shape before taping it onto a large drinks bottle and blasting it with a hairdryer! For the ‘bumps’ I have slowly dug a egg cup up from under the surface while keeping it heated from the other side. When done long enough it should maintain it’s new shape even when relaxed. You can also just simply fold something for a few days and it stays curved but I'd recommend the heat method for longer lasting results.

As you can see in the picture they are still unfinished as it will need several more coats of paint and then be glossed with several layers of PVA glue. In fact I would like to play around with different paints for a more metallic effect! I have heard good things about rub'n buff for a more finished look!