Crafting suits of armor from foam is a topic I cover semi-regularly because it’s knowledge that can completely change the way people cosplay. If you know you can build any armor you see, the number of characters you can cosplay as increases significantly. Bill Doran of Punished Props has a lot of experience using EVA foam to make epic looking armor (even to the point of making foam look like hammered metal) and has shared his knowledge via helpful videos and tutorials. He’s also written ebooks on the topic and has compiled those ebooks into a 184 page printed book called Foamsmith. It covers every step of making foam armor from design and templates to finishing to adding lighting effects. And, it helpfully includes over 400 photos.
The books is available for purchase directly from Punished Props.
These are a couple examples of armor built using Punished Props’ tutorials:
Costume by LaGuardia Replicas
Costume by Rev Chumley
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