Alternatives are always a good thing to keep in your back pocket in case you run out of different materials. So when it comes to crafting costumes, you might be wondering how to make cosplay armor without EVA foam. If you found yourself in a pinch and out of foam or you just want something new to try, there’s a few materials to try. Here’s what they are how how they work with making cosplay armor.
Use Worbla to Make Cosplay Armor
Worbla can work well for breastplates, bracers or shoe covers that looks like armor. It’s also very easy to get it to shape perfectly to your body and wear comfortably. In order to shape Worbla you just need a heat gun to warm and transform your material. You can also use plastic pellets or more Worbla to add detailing. Sculpting tools and heat stamping can also be used while warming the material. However, Worbla can also be more expensive than EVA foam and more fragile. This is probably one of the best solutions to the question of how to make cosplay armor without EVA foam though.
EVA Foam Alternative: Foam Floor Mats
This may seem like cheating having this alternative listed. But it isn’t actually EVA foam and is an alternative to it. The foam floor mats you see used for gyms or sold at Home Depot can be used just like normal EVA foam sheets. There will be a textured side that you’ll want to have facing inward in your armor. Otherwise it works exactly the same.
Using Cardboard
Some people already use cardboard to build armor. This one isn’t my favorite alternative. Cardboard doesn’t look as clean or smooth and cannot be textured or shaped as easily. I personally recommend using cardboard just for a base and then covering it in either fabric, foam or Worbla. However it still can be used as an alternative.
3D Print Cosplay Armor
If you happen to be a lucky cosplayer with a 3D printer and the know how on using it, then you can print off armor instead. Doing so just requires printing, assembling the pieces, sanding the print and then painting and sealing it. A few things to keep in mind though, 3D printed items are much heavier than foam made ones. If you’re going for large armor pieces, you might want to reconsider 3D printing it because it will be hard to wear.
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