Picture of Creating a Costume/Cosplay from E.V.A Foam

Good evening Ladies and Gents, In this fine Instructable I will be showing and instructing you how to work with EVA Foam for costuming and prop creation.

If you have any questions regarding the tutorial, making of your own cosplay/costume or just want to say hi please send me a message on my facebook page ( Its much easier and faster to get back to you there. :)

Over the several steps listed here ill demonstrate a handful of good techniques when working with EVA foam for the new and experienced cosplayers or costume enthusiast. Ill be demonstrating cutting, forming, edging, gluing and a few other tricks. I learn better ways and new techniques every time I do a costume so check back often for improved or new tricks and examples.

What you'll need!

EVA foam
Poster card/ card stock
Xacto blade/Razor knife
Hot Knife
Heat Gun
Soldering Iron
High temp Glue Gun
Rotary Tool
Nylon Straps
Velcro/Hook and Loop
Metal ruler
Fine point marker
Latex Caulk
Plasti dip
Spray paint

So lets get started!

I do not claim ownership of all the reference material such as product images and the space marine images. these are used as examples to help display what is needed and can be done with the material. All credit goes to the respected owner.

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NekuPOWER1 year ago

I'm a newbie when it comes to armor but I decided to give it a try! My dad have a lot of tools and I bought some good foam recently, I will certainly start tomorrow!
I found a "modest" armor in Monster Hunter tri that will be fun to make!

Your article is very clear, English isn't my first language but I can understand it very well! :)

Towering Props (author)  NekuPOWER1 year ago
Your are welcome! Thats what im here for. If you have any questions feel free to send me a message on facebook!

Hobby Lobby is owned by terrible people. You should use Michael's instead :)

Support companies who deserve it, here's the link so you can replace the Hobby Lobby one.

TiffanyC322 days ago

Great walkthrough, thank you for taking the time to type it out! I was just googling "EVA foam" and your link was the first one that popped up, how fantastic.

Quick question regarding the different types of foam featured in your walkthrough: what's the texture like on the underside of the fatigue mat EVA foam sheets? I'm eyeing the 0.25" pieces for example. My current project requires a smooth finish like craft foam but fatigue mats will have a textured surface (for obvious reasons). Do you know if the underside is smooth or textured?

Towering Props (author)  TiffanyC322 days ago
Hello! Thanks for the support! As far as i've come across all EVA has a textured side and a non texture side which is smooth. So yes it should work just fine for what you need.

Thank you so much for your fast response! I can only hope my armor turns out as amazing as yours. Fantastic tips all around, I can't wait to get started!

I would like to make some pieces look like leather. Any suggestions?

Towering Props (author)  diane.teeter.523 days ago

Hello! Hmm yes well leather is one of those materials that only leather looks like leather. I have had minor sucsess using really thick craft foam and putting mutiple layers of plasti dip on it. Krylon makes a paint color called "Brown Leather" and it looks kinda convincing. I would recommend that technique if your attempting a leather look with EVA.


Lubaaas1 month ago

I would like to make a fully round helmet, a ball shape with a diameter of about 35cm. Do you think this would be possible with EVA foam? Or should I try a papier-mâché solution instead? I'm going to give it a try anyways but tips are always welcome :-)

Towering Props (author)  Lubaaas1 month ago
Hey! Totally possible what you need to do is cut triangles out of the foam in order to have it round it. Just experiment and use that heat gun and it should be possible!

That's a great idea, thanks!

MartinH101 month ago

Hey, This is a really nice article, can i thransfer it to our website? Http://, We are manufacturer of EVA foam, i would like to save this article in our knowlage base, is it OK?

Towering Props (author)  MartinH101 month ago

While i'm flattered you wish you use my article on your website the license restricts ANY commercial use and must be used in the same license. You may use this article located on the instructables web address for your knowledge base and link the address on your website to this article but as far as being used on your website I must decline and state the CC by-nc-sa license.

OceanWhisper2 months ago
hi ToweringProps, do you know if hot glue will hold button snaps, and what about attaching Velcro? do you think I'll have to use superglue or hot glue to make it stick? cheers :)
Towering Props (author)  OceanWhisper2 months ago
Hey! It will hold with the hot glue but not for very long. Hot glues adhesion is based on surface area and theres not much of it with a small snap. How ever if you attach a snap through a scrap piece of frabric then glue the fabric to tje piece itll last much longer. Also using a 2" square of velcro with a snap in the middle you get the best of both worlds. The friction of velcro and the security of the snap.

OceanWhisper2 months ago
hey again :D I hope you had a fantastic Christmas, and soon a happy new year. I have a question, what's a good way to attach shoulder guards to a corset-style piece? would Velcro on the inside of the foam attaching to straps work? ( dunno if that even makes sense? XD ) thanks
Towering Props (author)  OceanWhisper2 months ago
Hey! Thanks and a happy and safe new year to you! That's honestly what I would recommend. Might have to experiment a little bit but a solid strap across your shoulder and a solid strip if Velcro along it attached to the foam should work just fine. small buckles with elastic are also a good alternative if it doesn't hold like you want it too.

TerraP12 months ago

Hey I've been planning to start an armor but I'm completely boggled for a way to make the helmet with some short of visor as the rest of the armor is quiet basic

Towering Props (author)  TerraP12 months ago
Forgive me for not quite understanding but what are you trying to do? Do you want the shield that covers his eyes to be transparent so you can see? Or you aiming to add a visor?
keithpurdy913 months ago
You put in capital letters to not paint the inside of the armor. But i bought the multi colored foam. What is your reasoning for not painting the inside?
Towering Props (author)  keithpurdy912 months ago
Unless you seal it the paint will chip and sweat off and get all over you. In the long run its just a waste of time and money. Unless its visible from he outside theres no reason to paint it.

BenS83 months ago

Hi, could you possibly give me some more detail on how to make a harness? My costume needs one, but I can't quite figure it out

Towering Props (author)  BenS83 months ago
Basically what your creating is an H harness just out of stuff you can get at Walmart like buckle straps and luggage straps. The 1" straps you can get in the camping section at Walmart and the 2" buck straps you can get in the luggage section. buy cutting the 1" straps the the right size you can easily create an H harness for a couple bucks.
here's a picture of what a H harness looks like. (

Ok, Thank you, and by the way, your instructable is really helpful so thank you again!

Awesome instructable! Thanks! I wish I'd seen this before making a Destiny costume for Halloween. Well, there's still Fanime.

I need to make a belt and I was wondering what would be the best material. If I should use foam or something else. I was thinking foam would be better. If it helps at all, I'm cosplaying Tsubaki Nakatsukasa from Soul Eater.

Towering Props (author)  AlwaysYoursx3333 months ago
Yah i would reccomend the roll mat because it will be long enough to have the belt be one piece. Rather then glue mutliple pieces out of the tile foam.
I am making a costume for my six month old for a con. I am making a togpi what kind of eva foam should i use
Craft foam will be your best bet. Very flexible comes in many colours so you wont need to paint it, best of luck!
OceanWhisper4 months ago
Hi Towering Props. :) I only just (not even a week ago) discovered armor with Eva, and was wondering, should I buy thin or thick foam for some Skyrim armour? It costs too much to buy both, as I only have a part time job.
Towering Props (author)  OceanWhisper4 months ago
Hmm thats tricky... depends in the armor your looking to make. Say if you want to make deadric i would reccomend the rolls but if you wanted to make dwarven i would say the tiles.
Thanks anyway :) I eventually just spent the extra $10 to get a roll of the thin foam. I figured that I could just layer it. I've made one gauntlet so far :D also, do you know if I can make acrylic paint look more 'metal'? I'm not able to buy spray paints of any kind. Thanks

As a costuming ultra-newb I found this article incredibly informative and helpful. Thank you very much!

TaylorJ24 months ago

So I'm trying to build a Daedric armor cosplay, how do you recommend doing the horns, or horns at all?

Towering Props (author)  TaylorJ24 months ago
You can do horns no problem. Think of them in strips, the more strips you have the rounder it will be. Say a pentagon has 5 sides but a hexagon has 6. The hexagon appears much rounder then the pentagon, so the more strips you have the rounder the horn. Also using latex caulk will help fill the seams of the foam to further help round the pieces.
MathewMatangi4 months ago


I was Just Wondering what is the best Foam thickness for making a helmet? I'm gonna make a Star-Lord helmet from guardians of the Galaxy using pepakura and was wondering if you need a certain thickness, please reply if you can :)

Towering Props (author)  MathewMatangi4 months ago
Hey thanks for the question!

I highly reccomend using the roll mat as the thickness will allow plenty of room inside the helmet while still being strong and keeping shape.

BW25 months ago

You used Plasti dip for sealing. How about Modge Podge? This is what I'm using but if there's a good reason why the dip over Modge Podge then I might try it. thanks for sharing your instructable, I'm buying a heat gun and wood burning tool now!

MelissaR7 months ago

I'm totally new to cosplay but have been watching many videos and I'm super eager to give foam armor a try! I've been to all the craft stores in my area and can't find any decent foam (why craft stores don't carry large amounts of foam is beyond me). But I was wondering if yoga mats are a suitable alternative for a beginner? Also, if they are, are there any different tips to using them than regular EVA foam…or is there a huge difference? Thanks!

BW2 MelissaR5 months ago

If there's a Michael's craft store near you, they sell the rolls of thin craft foam. You may have to ask them for it since it's usually hidden away.

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