How to Add Fasteners & Attachments to EVA Foam

Making your armor wearable or easily attach to other parts can require some tough engineering. Choosing the right fastener, adhesive and more is a lot of decisions to work through. This guide will show you how to add fasteners and attachments to EVA foam so they remain secure and ensures you used the right fastener for your costume.

Types of Fasteners & Attachments for Cosplay Foam

• Snaps
• Buckles
• Velcro
• Zippers
• Chicago screws
• Magnets
• Grommets & lacing

What Adhesives & Techniques Should be Used to Attach Fasteners to EVA Foam

• Adhesives – Super glue and contact cement are by far the strongest and best adhesives for attaching fasteners to EVA foam. Hot glue can also be used but is better for fast, less strenuous holds.
• Sandwiching or backing – For high-stress areas (pulling apart snaps), have a small piece of fabric or foam to sandwich to the fastener strap, gluing it over the attachment point to help avoid rips and tears.
• Sewn in – Some attachments can be sewn in. Create fabric pouches to sew in hidden magnets, use straps to sew buckles in place or sew directly into snaps, Velcro and zippers to secure them to your foam. This works better with thinner foams or hand sewing.
• Embedding – Using a Dremel or hot iron, you can create recesses in your foam to better embed your magnets. This avoids gaps and ensures everything rests flush.

How Do You Attach a Zipper to EVA Foam

Zippers are good for closing chest armor, bracers and more so you’re able to securely wear your foam armor. These tips will have you attach a zipper to EVA foam without risk of tearing and ensure a perfect fit.

• Use a separating zipper
• Contact cement or super glue are the best adhesives for foam and zippers
• Make sure your zipper is slightly longer than the opening before attaching
• You can sew an optional non-stretch fabric or ribbon to the zipper to reinforce the attachment
• Make sure to keep the zipper teeth a tiny bit away from the edge of the foam so it doesn’t get stuck
• Make sure you line up the zipper to face outward

How Do You Attach Velcro to EVA Foam

Velcro is great for attaching capes, details and other armor pieces to larger armor pieces. It can also be used like a zipper to close bracers, armor straps and closing chest armor. There’s a few tips to securely attach your Velcro to EVA foam.

• Adhesives like contact cement and super glue work best for velcro. Some velcros have an adhesive backing but it often isn’t strong enough
• For heavy-duty parts or high-stress attachments, use outdoor Velcro for a stronger hold
• With thinner foams, you can also sew the Velcro to the foam for a mechanical connection over a chemical one
• For maximum security, consider a fabric back that you sew to the Velcro and then glue to the foam

How to Attach Snaps to EVA Foam

Snaps are often meant to be sewn into fabrics. But they can also be attached to EVA foam to help attach capes, straps, leather and other small fabric pieces to your foam armor.

• You can use fabric backing to make the attachment more secure. Sew your snap onto either a piece of fabric, leather or ribbon and then attach that to the foam
• Use contact cement or super glue for your adhesive
• If you are using thinner foams such as 2 or 4mm, you can hand sew the snaps in place
• You can also explore magnetic snaps for a stronger connection
• When separating the snaps, if you notice they aren’t coming apart easily, use a small screwdriver to help separate to avoid pulling them off the foam or fabric

How to Attach Elastic Straps to EVA Foam

To comfortably wear foam armor, you can add elastic straps.

• Contact cement or super glue are the strongest adhesives for this attachment
• You can also add hot glue along the edges of attached straps to help secure it
• Try the sandwich or patch method to secure your connection. After gluing the elastic strap in place, cover it with a small patch of 2mm foam or fabric that you glue over the elastic

How to Add Magnets or Magnetic Snaps to EVA Foam

Magnets are a great way to attach pieces, close armor and more. With the right strength magnets, you can ensure nothing falls off, or you can splurge for the magnetics snaps for added security.

• Create an inset in your foam with a rotary tool so the magnet can sit flush or slightly below the surface
• Super glue and contact cement are the right adhesives for magnets or magnetic snaps
• You can also use an encased or sandwich meth by adding a thin layer of foam or fabric over the magnet
• Make sure the magnets properly align or they may not stay connected

Can You Use Screws in EVA Foam

There is a specific type of screw that works as a fastener for EVA foam. They are called Chicago screws or post screws. By properly installing them, you can ensure a strong attachment for your armor.

How to Add Chicago Screws or Post Screws to EVA Foam

• Step 1. Punch a hole slightly smaller than the post into your EVA foam
• Step 2. Push the screw post through the hole
• Step 3. Screw the backing onto the post
• Step 4. Place a washer for reinforment to prevent pulling.
• Step 5. You can now screw the fastener in place with a screwdriver to add an attachment

How to Add Buckles to EVA Foam

Buckles can also work well for attachments, such as my Sylvanas pauldrons and quivers to the cloak, or for closing armor. Make sure to use these tips for a secure connection:

• Always add a strap to the buckle that can be adhered to the foam. You never want to glue directly to the buckle
• Use contact cement or super glue to attach buckle straps to foam
• You can sew in the buckle straps for thinner foams
• Rivets or hardware, like Chicago screws, can be used to secure the buckle straps to foam

How to Add Grommets to EVA Foam

If you want your foam armor to close with the laced up look, add grommets to it.

• Grommets can be added to foam just like fabric, via a punch or anvil set
• Be careful not to get too close to the foam edge or the grommet may tear it
• Be gentle when punching the holes and grommets to avoid tearing foam

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