Introduction: How to Make Your Own Worbla

Picture of How to Make Your Own Worbla

Hey Cosplayers, in todays apprenticeship on Forging with Thermoplastics, I'll be teaching you how to make your very own Worbla! No more Paying an arm and a leg, this stuff is even better than worbla, I call it PolyArmor!

Step 1: Watch the Video


Begin this Tutorial by watching the video!

Step 2: What You Will Need


Polly Plastics Moldable Plastic

White Baking Flour

That's All, super easy recipe eh?

Step 3: Assemble Ingredients

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Take Equal Parts of both the Polly Plastics Moldable plastic and Baking Flour

Shake them together well in a Tupperware dish.

Then spread the mixture out into a thin circle on a cookie sheet

Step 4: Bake Your Mixture

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Set the oven to 350 F

Place your mixture in for about 10 Minutes or until the plastic pellets turn transparent.

Step 5: All You Knead Is PolyArmor ;)

Picture of All You Knead Is PolyArmor ;)

Pull it out of the oven and let it cool for a moment until you feel comfortable handling it to blend it together and knead it all.

Don't let it sit too long though or it will be too hard to work with and you will have to reheat.

Step 6: Roll It Out Flat

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Using a Pasta maker or a rolling pin, roll out the "dough" into a nice flat smooth sheet of your desired thickness!

Step 7: Finishing Touches

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The beauty of PolyArmor is that unlike Worbla PolyArmor is very smooth already and requires no layering priming, sanding, or sealing before you can paint it. You can just paint it and it has a beautiful sheen!

It's better than worbla, it is PolyArmor!!!

Get your plastic here to make some of your own!

Step 8: Conclusion

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If you love this apprenticeship, maybe you will love some of my other ones


wnorman (author)2017-09-11

just a small point the White Baking Flour you say is Self Raising flour or is it plain flour as both are classed as Baking Flour's

jallan5 (author)2017-07-13

I did some math and I'd just like to point out that making your own worbla might not necessarily be cheaper. If you only have $30 to spend on cosplay supplies and you want worbla, then yes, the DIY IS cheaper. Figuring from your vid (and great job by the way, your finished product looks fantastic) it looks like you got about 60 square inches of sheeting out of 2 ounces of pellets. Figuring that the cheapest I've found the pellets online is $15 per pound, that comes out to 3 cents per square inch. A small sheet of worbla from cosplay supplies comes out to almost 10 cents per square inch, so the savings is significant. However if you go up to a jumbo sheet, the cost is 3 cents per square inch! There is no similar volume discount that I can find anywhere with the pellets. So if you need a lot of the stuff and you have the cash, the official product is the way to go, given the convenience and consistency.

Of course, making a better product, something that fits the needs of your project is super cool. But if you are considering making worbla, just to save money, I'm not really sure it's worth it.

LARPkitten (author)jallan52017-09-02

Yes, but with Worbla, you also have to figure in the additional cost of the gesso, bondo, primer, and what-have-you to get it to be as smooth and paintable as the finished product in this tutorial. So even though bulk Worbla is the same base cost as this material, you're still paying more for the materials needed to bring Worbla up to the same level of quality in the finished look.

Horolaggia (author)2017-01-13

How much of each did you use in the video? I'm trying to work with this for the first time and would just like to know how much of the plastic to use per sheet? Like, a tablespoon of plastic + a tablespoon of flour or is it more?

GenevieveH3 (author)2017-01-01

How much of the pellets did you use to create one "sheet"?

TrishaB19 (author)2016-12-12

I keep seeing poly plastic pellets "cornhole blend" is there any difference, or is that the same

Iskelderon (author)2016-11-17

Quite interesting! What's the shelf life of this? Won't the flour component spoil over time?

mmalaske (author)2016-10-20

Great tutorial! I recently bought Worbla and I'm excited to try making some myself and save a little $$$. Couple questions for you:

1) Does it matter if you use whole wheat flour or white flour?

2) Since flour does go bad after a while does PolyArmor have a shelf life?

I would presume that if you had worries of it going bad you could use talc or baby powder, or something like sawdust (wood pulp is actually one of the materials in Worbla).

wnorman (author)2016-09-24

Could you put the tempretures in c as well as not every body knows the convertion rate

saladgyrl (author)wnorman2016-11-02

you can also look online for a conversion chart...I have to.

176 Celsius :)

tazmo8448 (author)2016-09-29

guess if I have to ask what a Worbla is I don't need one

Hahaha :) Worbla is a thermoplastic sheet frequently used by Cosplayers to make armor, but it can have many other crafting and DIY uses as well :)

thanks for cluing me that some sort of Dungeons & Dragons sort of thing? or just a overall role playing deal.

Just general Cosplay, Movies, Comics, TV Shows, Games, any kind of fandom :)

syates3 (author)tazmo84482016-09-30

From the Pages of the Worbla bible....

That is awesome!! Who made that?

tazmo8448 (author)syates32016-10-01

thanks for the heads up..

NotACat (author)2016-09-29

This looks really fun, but Polly Plastics don't ship outside the USA. Does anyboyd know of a UK equivalent?

Also Polymorph I think is available in the UK and I believe is pretty close to the qualities as Polly Plastics :)

BVBfangirlqueen (author)NotACat2016-09-29

try instamorph, or friendly plastic.

mizrie (author)2016-10-02

Fantsstic money saving idea! I am in the UK, is Polymorph Plastimake the same thing as Polyplastics mouldable plastics?

Polymorph would probably be a good alternative to Polly plastics if you live outside of the US. They are both PCL and I think that their qualities are similar.

datajunkie55 (author)2016-09-29

I'll be trying this shortly. Might also try mixing in some hot melt adhesive powder I have. The sort used as thermal adhesives. Basically a hot melt glue stick or sheet in a fine powder form. I suspect only a small amount would be needed to increase self sticking. I will need to check the melting point of both first. I have instamorph plastic on hand.

If you use instamorph you may need to try and increase the self sticking but if you use Polly Plastics it will stick to itself better than worbla already without any adhesive backing :)

Korzer (author)2016-09-22

thanks buddy, for this great Instructable. I always wanted to buy some Worbla to build my own cases and Boxes, but it was way to expensive for such an experiment. This instructable make it way cheaper. Can I take any Plastic Pallets?

You are most welcome! Glad it was helpful! I would strongly advise getting the Polly Plastics pellets because not all the PCL's I have worked with have the qualities that makes it able to take the amount of filler I recommend and still remain able to stick to itself like Worbla. :)

Wolfbane221 (author)2016-09-22

this is an interesting idea. can you heat up the edges to join them like thermoplastic before the mixture?

Yep you can them them up adhere them together anyway you want. No glue needed! :)

seamster (author)2016-09-22

This is a really neat idea. I've been thinking about picking up some worbla at some point.. but I've already got a couple packs of thermal plastic beads. Might have to give this a shot.


For sure! let me know how it goes!! :)

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