Not all foams are the same. Comparing things like craft vs EVA foam, thickness and even density are vital choices you have to make while building your cosplay. If you aren’t sure what you need to use for your prop or armor build, I’ll help you compare. In order to make the right choice, we need to understand what is the difference between low and high density EVA foam.
What is High Density EVA Foam
This EVA foam has a higher density and thus has tighter, more compact cell structure than craft foams. It’s used for cosplay because it’s strength, durability and how smooth it is. It’s considered ideal for armor, props and detailed builds. It’s the firmest foam you might use as a cosplayer and holds structure well.
High Density EVA Foam Pros & Cons
Pros:
- Durable – Because of it’s composition, it better resists dents, compression and wear thus making it incredibly durable.
- Holds shape – It can hold shape well and thus makes it great for pieces like armor and helmets.
- Smooth – The surface texture is very smooth which is ideal for cleaner painted finishes.
- Sands clean – When you carve or sand with knives or Dremel, you will get very clean and crisp edges. You can also expect fine detail work when you carve.
- Warps less – Even with heat or movement, the form will maintain over time and you don’t run the risk of warping.
Cons:
- Stiff – This foam can feel bulkier to wear because it’s often heavy and stiff.
- More work to shape – You will need more heat to truly shape the foam. Thus it’s a lot more work to shape it how you need.
- Harder to cut – This foam is very firm and can be more difficult to cut. Make sure your blades are sharp to get clean cuts.
- More expensive – This one costs more than craft and low density foams.
What is Low Density EVA Foam
This is a softer and lighter EVA foam. It’s very easy to cut, bend and shape. This is because it has a far looser cell structure than high density foams. Cosplayers often use it for flexible costume pieces, accessories and layering. It’s great for areas of armor where comfort and movement is a greater priority than rigidity and durability.
Low Density EVA Foam Pros & Cons
Pros:
- Lightweight – The material is very lightweight making it easier to wear and move around in.
- Flexible – The foam can move with you and works great for joint areas of armor.
- Easy to shape & cut – Due to how light it is, it’s far easier to shape and cut.
- Comfortable – It bends very naturally and can be far more comfortable to wear at cons and for long periods of time.
- More affordable – It’s often cheaper than high density foams.
Cons:
- Less durable – This foam can easily tear, warp and dent because it just isn’t as strong to withstand wear and tear.
- Doesn’t sand as well – The softer texture makes sanding and carving this foam far less clean.
- Loses structure – Overtime, the foam will lose structure since it doesn’t hold shape well.
Low Vs. High Density EVA Foam
Now that we understand, what is the difference between low and high density EVA foam and what the two materials are, we can make a more educated choice on which to use for our cosplay. Each one has different pros and cons as we discussed and thus has different purposes. Keep in mind, many cosplayers will combine both types of foam though and you still need to decide what thickness to use.
When to Use High Density EVA Foam
- Armor plates – Chest plates and pauldrons are great for high density foam because of how well it holds curved shapes.
- Helmets – These are rounded, shaped pieces that also will benefit from high density foam and it’s ability to hold dome or curved shapes.
- Weapons or props – When you need clean sword blade edges or more rigid props, high density foam is a great way to go. Otherwise more lightweight foams could fail to hold shape for larger props.
- Bases – To have a durable, structural base, use high density foam. It makes a great foundation that you can layer on and maintain stability.
When to Use Low Density EVA Foam
- Flexible armor parts or undersuit – Things like knee or elbow pieces where your joints are need a more flexible material so you can move around, use low density foam.
- Layered details – Thin layers or small details can easily be glued onto other foam and surfaces to add detailing without making your cosplay too bulk. It also will more flexibly shape or curve over whatever you glue it to.
- Lightweight props – Smaller, handheld props or little accessories can be done out of low density foam to keep them more lightweight while you carry it around.
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