Craft/EVA Foam
- Cost effective durable armor
- heat set easily
- widely available
- must be sealed before painting
- Variable thicknesses
- http://entropyhouse.com/penwiper/costumes/helmsdeep.html
- COST: 50c – $2 /sqft
- Vendors:
- Craft stores (Jo-Ann, Michael’s)
- Hardware stores (Harbor Freight)
- http://www.createforless.com/Foamies-Foam-Sheet-12-x-18-in.-2-mm.-Black/pid9575.aspx
PVC or PEX Pipe
- Good for weapons
- Support large costumes
- PVC stiffer and straight
- PEX has natural curve
- http://www.solidsmack.com/design/the-star-wars-tauntaun-costume-with-a-little-help-from-solidworks/
- COST: 30c /ft
- Vendors: Home Depot, Lowes, Hardware Stores
Insulation Foam
- Lightweight
- Good for weapon base
- Needs sealing for strength
- http://xxsnowfrostxx.deviantart.com/art/WIP-Ryuko-Scissor-Blade-Tutorial-429852727
- COST: $1.50 /sqft
- Vendors: Home Depot (pink), Lowes (blue)
Styrene
- Vacuum Forming
- Good for simple curves
- Flat surface, easy to finish
- Needs support behind it
- http://researchanalyst.hubpages.com/hub/Cosplay-Armor
- COST: $2 /sqft
- Vendors:
- Hobby stores, craft stores,
- http://www.hobbylinc.com/
- http://www.cosplaysupplies.com
- http://www.amethyst-angel.com/armortutorial/styrene.html
Sintra/ PVC Sheet
- strong and durable but also flexible
- heat moldable (take caution of fumes)
- paintable
- https://cosplaybrain.files.wordpress.com/2013/04/expanded_pvc_basic_armor_tutorial_by_nyunyucosplay-d5xy715.jpg
- COST: $3 /sqft
- Vendors: http://www.foamboardsource.com
Fosshape
- felt texture, can be sewn
- Heat with iron/gun
- Strong & Lightweight
- Can be painted, covered
- Will shrink up to 10%
- https://www.cosplaysupplies.com/tutorials.php?id=12
- COST: $4.50 /sqft
- Vendors:
Wonderflex
- Good for armor/weapons
- Layer for extra strength
- Paintable
- Can’t do complex curves
- Fabric mesh layer stronger
- http://www.instructables.com/id/Creating-Costume-Armor-with-Wonderflex/?ALLSTEPS
- COST: $12 /sqft
- Vendors:
Worbla
- Good for armor/weapons
- Layer for extra strength
- Paintable, sandable
- Complex curves
- Bonds to itself when hot
- Scraps can be reused
- http://www.cosplaygen.com/how-to-work-with-worbla/
- http://www.kamuicosplay.com/product-category/books/
- COST: $15 /sqft
- Vendors:
Casting Materials
- Create personalized molds
- great for making many duplicates
- Durable, high quality
- Quick, some in 10 mins
- Expensive, intensive prep
- http://www.smooth-on.com/gallery.php?galleryid=272
- COST: 75c /floz
- Vendors:
Instamorph
- moldable pellets activated by hot water
- reuseable/no scraps
- bonds to itself when hot
- can be rolled into sheets
- can be pigmented
- COST: $1.50 /oz
- Vendors: http://www.amazon.com/InstaMorph-Moldable-Plastic-12-oz/dp/B003QKLJKQ/ref=sr_1_2?s=arts-crafts&ie=UTF8&qid=1427983879&sr=1-2&keywords=instamorph
Misc Links: