Batman Foam Armor

Here we go…

My wife wanted to make a Poison Ivy costume for Halloween this year and thought I should be Batman. Thats where it got crazy. Knowing my self I couldn't go buy a Batman costume at the local shop so I started studying up. I determined that I could make a pretty sweet one on my own. After determining what I was up against, I took a trip to a local craft shop for some foam sheets for $1 a sheet, an exacto knife $7, and some hot glue (already on hand). So here is what I have come up with. Hope you like what I have come up with.

Items used:

5 5mm foam sheets from the craft store $1 each

2 2mm foam sheets $1.50? each

Exacto knife with 5 blades $7

Scissors you all have some…

Glue gun with a bunch of glue sticks



Cutting board

The drive to have a sweet Batman costume.

Step 1: The Breast Plate

So I began with the thicker sheets of foam (5mm) and came up with a good shape. I cut two pieces roughly the same size and beveled the edges on the top sheet. I mocked up the layout here and have cut out the bat emblem. After cutting the two sheets I was able to shape them by hand by simply by molding them how I wanted. I glued them in place using a hot glue gun.

Step 2: Joining the Pieces

After getting the pieces glued, I layered a thin sheet of foam (2mm) over the two pieces by cutting a rough outline. I placed this sheet over the entire piece and trimmed the edges after gluing. Take your time on this and do the body, then edges one at a time to ensure a good fit/coverage. Once the two pieces were covered I cut a piece to join them together. This is seen at the top of the pieces it ads some detail that the Bat logo will go on. Again take time and glue the body and then the edges. After this is glued add on the Bat logo by channeling your inner OCD and make sure it lines up properly. I did not glue the center of the bat as it floats over the center crease.

Step 3: Get Some ABS!

I made some abs with the thick foam and added some details with the thinner foam as in the previous step. I liked this look but get crazy if you want.

Step 4: Legs

I came up with a shape I liked for some thigh protection. I notched out the bottom for knees. Both of these are out of the thick foam. The top sheet is beveled to make it a smoother transition. I would suggest shaping these slightly prior to gluing.

Step 5: Where I Am at Now

So this is where the project is at currently after a days work. More pictures and steps will come shortly. I made some simple knee pads out of the thick foam and beveled the edges with the exacto knife.



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    5 Discussions


    3 years ago

    Nice. I made a costume like that a couple years ago. it was super fun. I think I'll do another one because I had so much fun.


    Reply 3 years ago

    For some of it I have modeled it after the actual batman suit, but mostly it has been straight out of my head.