EVERYTHING ABOUT
EVA FOAM
No matter your project, EVA foam offers unmatched versatility and adaptability. With the right tools, techniques, and know-how, this material empowers crafters to bring their visions to life—whether it’s creating iconic cosplay armor or stunning stage props.
A favorite among cosplayers and prop makers, EVA foam is lightweight, flexible, and easy to work with. It cuts, carves, and heat-shapes effortlessly, making it perfect for creating armor, weapons, and intricate costume details.
Its adaptability is a major strength—it can be sanded or textured to resemble metal or leather, yet remains impact-resistant and comfortable to wear. Whether you're crafting an elaborate cosplay or a custom prop, EVA foam offers professional results without breaking the bank. With a bit of heat and creativity, the possibilities are endless!
Its adaptability is a major strength—it can be sanded or textured to resemble metal or leather, yet remains impact-resistant and comfortable to wear. Whether you're crafting an elaborate cosplay or a custom prop, EVA foam offers professional results without breaking the bank. With a bit of heat and creativity, the possibilities are endless!
WHAT IS EVA FOAM?
EVA foam (Ethylene-Vinyl Acetate foam) is a versatile, lightweight, and durable material used by crafters, cosplayers, prop makers, and foam smiths. It can be cut, shaped, and heat-formed to create detailed designs, but working with it safely is essential. Sharp blades, heat guns, and contact cement are commonly used, so proper precautions are key.
Always wear PPE such as gloves, a respirator, and eye protection, especially when using adhesives or heating foam, as vapors can be harmful.
EVA Foam Is Perfect for
Costumes and Props
Lightweight and Comfortable
EVA foam is ideal for wearable projects like armor and helmets because it’s lightweight enough for extended use without causing discomfort.
Durable and Flexible
Despite its lightness, EVA foam is strong, bendable, and resistant to wear and tear (to a certain degree).
Affordable
EVA foam is a cost-effective solution for creating high-quality props and costumes without breaking the bank.
Highly Customizable
You can cut, heat-shape, sand, carve, paint, and texture EVA foam to mimic materials like metal, leather, or wood.
Con-Safe
EVA foam props are lightweight and safer for conventions compared to heavier materials like wood or metal.
EVA FOAM THICKNESS
& DENSITY
Thickness
EVA foam comes in various thicknesses, from thin, flexible sheets to dense, sturdy blocks. Thinner foam is great for details and layering, while thicker foam provides structure and durability. Choosing the right thickness depends on your project’s needs, balancing flexibility and support.
2-4mm
Best for intricate details, small accessories, or adding layered textures
5-8mm
A versatile choice for medium-sized props, armor, and general-purpose crafting.
+10mm
Perfect for thick, sturdy elements like weapons or large, durable props.
Density
Density affects durability, flexibility, and detail. High-density foam is firm, holds shape well, and resists dents, while low-density foam is softer and easier to heat shape. The right density depends on your project’s balance of strength and workability.
Low
Quite soft and more flexible, super easy to heat shape. Doesn’t hold details quite well
Medium
A balance between flexibility and structure, good for general armor and helmet crafting
High
Very rigid, easy to sand, but super hard to heat shape. Holds detail well, and is very durable.
How to Choose the Right EVA
Foam for Your Project
Props and Weapons
Use thicker foam (8mm–12mm) for structural stability and durability.
For fine details or layered textures, opt for thinner foam (2mm–5mm)
For fine details or layered textures, opt for thinner foam (2mm–5mm)
Armor & Helmets
Medium-thickness foam (5mm–8mm) works best for wearable pieces that balance strength and flexibility. Consider high-density foam for sharp edges or intricate details.
Accessories and Small Details
Use 2mm or 3mm foam for creating lightweight accents or intricate patterns.
Flexible vs. Sturdy Needs
For projects that need to bend, like capes or horns, go for low-density foam. For rigid structures like weapons and armor high-density foam ensures durability.
WHERE TO BUY EVA FOAM
Cheap EVA foam is widely available on platforms like eBay and Amazon, making it easy to get started. EVA foam floor mats, often found in hardware stores, are an affordable and excellent material for beginners to practice with.
For higher-quality foam in various thicknesses and densities, specialized online shops offer better options for serious crafting. Some great suppliers include:
For higher-quality foam in various thicknesses and densities, specialized online shops offer better options for serious crafting. Some great suppliers include:
