Cosplayer Charmanda picked an Overwatch ensemble for her first-ever costume. She crafted Pharah’s Raindancer skin. After she patterned the armor pieces, she worked on a strap and harness system to wear underneath the armor to keep it all in place. Expanding foam was a key material in the build. She crafted both the armor and Pharah’s gun from the foam and had to cut it down and sculpt it. She covered the smoothed expanding foam with a different kind of foam: EVA. You can see a little of the process below.
See more making-of photos in this Facebook album.