Trying to pick the right materials can sometimes be the hardest part of making a cosplay. So what is considered the best EVA foam thickness for cosplay? The answer will vary on what you’re making. I personally feel 10mm foam is the best thickness, but for some projects, it isn’t the right choice. That’s why we’re going to explore the many sizes and what they work best for.
1 – 4 mm EVA Foam
This is the thinnest EVA foam you can purchase. This is not the best thickness for crafting armor or large props. However, it is the perfect size for adding thin layers and fine details. This foam can also be great to work with a laser cutter for cutting out multiples of detail pieces like foam feathers or scales.
5 – 8 mm EVA Foam
This is the size I often prefer to have on hand since it can have many uses. It can work to creates quiver bases, thinner armors (to appear like leather) or helmets, creating fake leather, belts and pouches, and even props like daggers. I’ve also personally used it for crowns, hatchet heads, machetes and Pokemon balls. It’s most versatile for props by far but can also have use in creating detail pieces too.
10+ mm EVA Foam
This foam is essential for medium and large props such as guns and for most armor. Armor from a variety of media like Skyrim, Game of Thrones, Dune and more will require 10mm or thicker and creating pistols and rifles of all varieties as well. It ensures the armor and props is the proper thickness. In theory you could use thinner foams for prop guns, however it’ll take far more layers than if you just used 10mm or thicker.
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