Sometimes it’s hard to find the perfect feathers for a costume. So this calls for creating our own. This guide will show you several different materials to choose from and how to make fake feathers for cosplay. So you can ensure they’re the perfect size, shape and color.
How to Make Fake Feathers from EVA Foam
Thinner EVA foam can be used for feathers. Especially if you want them to have more structure. I myself used them for my Sylvanas pauldron feathers.
- Step 1. Cut the foam – Trace out your pattern onto 2mm EVA foam. Then cut it out either with an exacto knife or scissors. You will also want to snip small, angled triangles along the edge to help shape your feather.
- Step 2. Score the foam – Lightly score a line down the length of the feather without cutting all the way through. This will be the rachis or stem. Then create more angled scores branched from the main line. This will help give it the effect of barbs in sections.
- Step 3. Heat and shape the foam – To shape the feather and heat seal it, use a heat gun. This can cause the feather to curl but it can be flattened back out by placing it under a heavy book for a while. Be careful not to overheat the foam since it’s thinner.
- Step 4. Paint the foam – To prevent filling in the scores, I skipped priming. You can then paint your feathers accordingly. I did also skip sealing to preserve the scoring and because I didn’t want it to have a glossy finish.
For larger feathers that you want to make posable, you can sandwich floral wire in-between two foam feathers.
How to Make Fake Feathers from Fabric
Make sure to use a fabric that works with HeatnBond.
- Step 1. Embroider the fabric (optional) – Before you begin making the feather, you can embroider a feather pattern onto the fabric. This is an optional step and can be skipped.
- Step 2. Add wire to the fabric – Sandwich the two pieces of fabric together with floral wire running down the center as a stem. HeatnBond can be used to attach everything together.
- Step 3. Cut the fabric – Cut out the feather shape. If you didn’t embroider the fabric, cut the fringe to give the feather edges a natural look.
How to Make Fake Feathers from Polyethylene Foam
This method is good for large wings where you need many feathers that look the same.
- Step 1. Cut the feathers – Cut out your feather shape. You can also cut to fringe the edges to create sections of barbs.
- Step 2. Color the feathers – Use an airbrush to paint your feathers as needed.
- Step 3. Assemble the wings – The feathers can be added to a wing base with hot glue by gluing down the bottom base of the feather.
How to Make Fake Feathers from Interfacing
For this method you will need fusible interfacing.
- Step 1. Add wire to the interfacing – Fold the fusible interfacing over floral wire and iron it together. The wire needs to be in the center as the stem and stick out at the bottom.
- Step 2. Cut the feather – Cut the feather shape into the interfacing. Add snips along the sides for the barbs and it make it more feather-like.
- Step 3. Dye the feathers – For better coloring, you can dye them and airbrush any additional details.
What is the Best Material for Cosplay Feathers
All of these options are great for making fake feathers for cosplay. However, each material has an application it’s best for. Overall, EVA foam or interfacing is probably the best option.
| Material | Cost | Durability | Weight | Best Application |
| EVA Foam | Average – Expensive | Durable | Light – Average | – Wings – Rigid armor accents – Stylized or cartoonish feathers – Small set or accent feathers |
| Polyethylene Foam | Cheap | Average | Light | – Wings – Collection of many feathers – Small set or accent feathers – Capes |
| Fabric | Varies by Fabric Type | Durable | Light – Average | – Capes and corsets – Draping feathers – Small accents |
| Interfacing | Cheap – Average | Fragile | Light | – Wings – Collection of many feathers – Small set or accent feathers – Capes |
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