Ultra-Lightweight Chainmail Out of EVA Foam for Your 'For Honor' Cosplay

Intro: Ultra-Lightweight Chainmail Out of EVA Foam for Your 'For Honor' Cosplay

Here is a really quick video of the process:

The steps that come up next are the cheat sheet you need to make this happen. :)

STEP 1:

To make the chainmail you will need to get some files and laser cut, cricut, CNC or what ever cutting method you prefer out of EVA foam. You can also 3D print the STL out of flexible filament if you want.

First you will need to download the files from this thiniverse post, or from this instructable. https://www.thingiverse.com/thing:3619166 There are many formats and hopefully I have made the one you need.

You will need to buy some 2-3mm thick craft foam or EVA foam. I get mine in rolls here: https://amzn.to/2PXNMYa

1. Laser cut the foam using the files at thingiverse or attached to this post out (if you have a laser) if not use what you have...
2. Knit the parts together like in the photos. You can also watch the YouTube video attached to see it in action
3. The knit pieces want to make a tube so use a heat gun to flatten the knit pieces you have
4. Add another couple strings of the laser cut pieces
5. Heat gun
6. Repeat
7. Repeat
8. Repeat
9. Until you have a sheet of light weight chainmail you can use.

STEP 2: Take Back the Holy Land!

Now with your newly made chain mail make some Armour to take back the holy land!

Some things to note:

• You can cut this out of pretty much any flexible material and have it work the same
• 3d printing with flexible filament is something I have not tried yet but am 99.999999% sure it would work amazingly
• Add a leaf to the bottom of the links and you now have dragon scale mail! (I will be doing this shortly and will up load the files for you.

First and foremost though. Make and have fun!

Comments

[DenP1]

for EVA foam, super glue or fast-acting nail glue (which is basically super glue with additives) makes a fast and strong bond to connect pieces together.

[The Cardboard Kitty]

Have you made wearable pieces with the chainmail? I’d love to see photos.

I’ll be trying this with a Cricut Maker. I haven’t tried cutting foam with it yet, hoping it won’t come out with burrs. My heat gun would probably diminish burrs, but not absolutely eliminate. When I try it I’ll post a photo.

[The Cardboard Kitty]

The first attempt was with a deep point blade, the second with a knife blade. Both done on a standard grip mat with a piece of vinyl (sticky side up) placed between mat and foam for stability. The results weren’t perfect, but as good as I expected.

[DorkyDuck]

I know you posted this a while ago, but do you remember what settings you used with the knife blade? :)

[MechanicalMashup]

Awesome! You are the first I know of to use a cutter. Love that it works! Thanks for sharing!

[Jamestown3456]

Interesting technique. To make sheets larger than the laser cutting bed, maybe you could weave each layer staggered by 3 to 6 inches to hold everything together. The cylinder of a shirt of mail could then be locked together the same staggered method.

[RaphaHey]

May I use this design concept to make my own armor products? I have a hobby community that is interested in fantasy looking chainmail armor, and I want to support my hobby and my community by manufacturing these links for profit. I'm not sure if there is any demand; I only know that there is interest, and hope I could sustain my hobby through sales/commissions. I would make tweaks and changes to adapt your idea to meet my community's needs and my manufacturing constraints. That being said, I have no clue if such adaptation would constitute a "new design" and because I respect your good creative work, I am asking for permission to use this design concept in my own efforts.

[onetruegod]

This looks like knitting rather than chainmail

[WileyCricket]

Brilliant!!

[AutumnrainChaos]

The laser cutter: i have access to an epilog laser engraver, what speed and settings did you use for your laser?

[Mr&MrsA]

Just watched a video on YouTube of you and Adam talking about this! Thank you ..... I think it’s you on his show!?