Many cosplayers use thermoplastics in their projects, and it seems as though the most popular one right now is Worbla. It can be used for myriad purposes and has become a must have material for that reason. Tandy Leather has recently released a new thermoplastic though: TerraFlex. It can be used in a similar fashion to Worbla since it can be shaped with heat and like Worbla, scraps can be heated and formed together. Tandy reports that customers have told them it’s smoother than other thermoplastics and requires less sanding. The above video highlights some the product’s properties. Tandy Leather also posted a short video showing off some TerraFlex basics at Facebook.
Alex Martin has been using TerraFlex to make some armor pieces for a Zelda costume for his fiancé. They started with a base of craft foam and melted TerraFlex over their design work. It looks like it holds the details well. I look forward to seeing more cosplayers experiment with the product.