Popular Materials for Cosplay Armor

Cosplaying is a serious business to a lot of hobbyists nowadays, and creating an outfit from scratch is no joking matter. In fact, you can become an instant celebrity if you’re good at the craft. These are the most common materials used by cosplayers for creating armor.

Foam

There are two popular types of beginner materials commonly used to create armor; craft foam and floormat foam. Each one requires different techniques and your preference will depend on the size, function, and design of the armor you’re cosplaying.

Craft Foam can be bought cheaply in rolls or sheets and is common in most hobby shops in Singapore. What makes them ideal for most cosplayers who need a full armor is that they are easy to carry around because they’re light. They’re also easy to shape and manipulate using heat, but they are not ideal for creating round pieces. It’s a flimsy material and needs resin or glue and fabric to make it last longer and to seal its porous surface.

Floormat Foam, also called EVA foam, is also cheap and is much lighter than craft foam. However, it might be challenging for beginner cosplayers because it’s more difficult to work with. It can be sanded, but you will need a respirator. It will also leave a lot of mess and it needs to be sealed before it can be painted. You’ll also need a lot of practice when cutting the floormat foam because it’s thick. Most of the seasoned cosplayers will opt for thermoplastic and PVC foam once they are more confident with their crafting skills.

Cardboard

Cardboard is used for papier mache and paper clay armor. Some cosplayers find these materials much easier to work with than the others, although they need the same level of skills to create a cosplay-worthy piece. For a cardboard armor, you will need the following additional items: newspaper, glue, papier mache paste or mix, paper tape or masking tape, gesso, and sand paper.

Casting and Molding

Casting and molding is an advanced armor-creation technique that will require knowledge of how to work with materials such as, plastic, resin, and rubber compounds. The most common resins used by cosplayers are polyester, urethane, and epoxy. The molds are usually made from scratch using either a putty or a paste, but the material will also depend on the type of resin you’re going to use to hold it in.

Advanced armor cosplayers go the extra mile by learning how to craft leather, chainmail, fiberglass, and other advanced materials. Even your skills at other crafts, such as dressmaking and sculpting, will also be a bonus when creating armor.