Worbla's Finest is a material that is hitting the world by storm! Easily manipulated, heat activated and as hard as plastic when cool - there is little else in this world that meets its usability. For this project, I will discuss creating the shoulder armor from the Diablo 3 Demon Hunter build I completed this past spring.

Here are the tools/materials you will need:

- A strong pair of shears (I use titanium)

- An Exacto blade

- 2mm EVA Foam

- 1 medium to large sheet of Worbla (purchase here: www.cosplaysupplies.com)

- Poster Board

- A marker

- A heat gun (or the ability to heat the Worbla - I hear warm water works as well)

- Paint brushes and Paint

- Mod Podge Clear Sealant

- A Pencil

Step 1: Step 1: Getting your patterns right

Everything starts with a pattern; whether you draw it yourself or use a program like Pepakura, a pattern is necessary to ensure consistency (especially with symmetrical pieces). Start off by drawing or tracing your pattern onto a piece of poster board. Cut out the pattern and tape or pin it together. How does it look? Is it the right size? You want to make sure you have the dimensions correct before you cut out the foam.

With the dimensions adjusted, take your new pattern and trace it onto your 2mm EVA foam (aka craft foam). Once your foam is cut out repeat the "testing" steps. Make sure it looks right and fits well. Now that you are positive about the fit trace your pattern onto your Worbla sheet (make sure the Worbla pattern is a little bigger than your foam pattern) twice. Why twice? Well, I use the sandwich method which means for every one piece of foam you need two pieces of Worbla.

If you don't have the funds for this method you are welcome to cut out one piece of Worbla a bit bigger than your pattern and simply fold over the edges when you get to the building phase (which is discussed in the next step).Foam

First let me say the armor turned out nice.<br><br>How different is it from abs? I vacuum form and can't really see much advantage unless its way cheaper by the sheet (haven't checked yet).
<p>Thank you! Abs are actually pretty easy. I have never used vacuum forming but I am familiar with it's process. For Worbla, all you would need to do is create a base layer of armor that is the length of your torso then cut out ab size squares from foam. Position the squares so they match your abdominal length/location and then lay another long sheet (just one) of heated Worbla on top. You should end up with something like what Folkenstal Armory created in the attached image. (NOTE: This is a VERY rigid product when set, it will restrict your movement so test out how low you want to go with it first).</p>
<p>I think he meant how it compared to using ABS plastic, not how to do lower torso armor. Basically, how does it compare to other heat forming plastics?</p>
<p>Oh! And the best thing about Worbla - it provides it's own adhesion so sticking parts together gets a whole lot simpler.</p>
<p>Ah. That makes sense. Sorry about that, lol. Let's see...it is a bit more flexible than vacuum formed plastic, it is about as tough as WonderFlex and a lot easier to manipulate. With other thermo-forming plastic you have to keep the heat applied consistently and manipulation can be difficult without the assistance of another, a mannequin or clamping tools. Worbla heats up quick but it remains malleable longer than other plastics. It's also less of a mess and if you make a mistake you can reheat, separate pieces, flatten and then reform them rather easily.</p>
Its interesting but I don't do much cosplay stuff. Everything that makes this ideal for your applications makes it the exact opposite for mine. Always nice to learn about new products.
<p>As far as cost, here is the general price sheet for Worbla from CosplaySupplies:</p><p>-Jumbo (Size 100cm x 150cm (39.25&quot; wide x 59&quot; long): $80.00 (free shipping, no tax)</p><p>- Large (Size 75cm x 100cm (29.5&quot; by 39&quot;): $55.00 (free shipping, no tax)</p><p>- Medium (Size 75cm x 50cm (29.5&quot; by 19.5&quot;): $34.00 (free shipping, no tax)</p><p>-Small (Size 37cm x 50cm (14.5&quot; by 19.5&quot;): $26.00 (free shipping, no tax)</p>
Cool, now maybe make the Akkhan set for my shotty cader? ;) I can't wait until 2.1!
Good luck with that! Worbla is alot of trial and error but errors are very easy to fix :)
<p>The armor is so cool looking! Thanks for explaining how to use worbla it's definitely intimidating for a beginner. </p>
Thank you very much! It can be intimidating but don't give up! It's very much worth it in the end.

About This Instructable




Bio: Cosplay enthusiast, illustrator, costume designer/creator, Worbla novice, IT nerd and all around excitably geeky chick!
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