How to make a baymax cosplay?

Materials Needed

• EVA foam sheets (various thicknesses)
• Hot glue gun and glue sticks
• Craft knife or X-Acto knife
• Heat gun
• Mod Podge or Plasti Dip (for sealing the foam)
• Acrylic paints (white, black, red)
• Elastic bands or Velcro strips (for securing parts)
• Sponge or foam padding (for comfort)
• Cardboard or Pepakura templates (optional)
• Sewing materials (if making a fabric-based costume)
• Black clothing (to wear underneath the costume)

Steps to Create the Baymax Costume

1. Designing and Planning

2. Creating the Body

Healthcare Companion Form

1. Inflatable Suit Base:
   1. An inflatable Baymax suit can serve as the base. These are available online and provide the iconic round shape of Baymax. This can be found on sites like Crazecosplay.com or Rank No.1.

2. Adding Details:
   1. Use EVA foam to create the access port on Baymax's chest. Cut a circular piece and attach it using hot glue.
   2. For the hands and feet, create simple mitten and boot shapes from EVA foam and attach them to the suit.

Armored Form

1. Chest, Back, and Abdomen:
   1. Measure and cut rectangles from EVA foam for the chest, back, and abdomen. Fold the paper in half to ensure symmetry, then cut out the shapes.
   2. Use a heat gun to shape the foam pieces and glue them together. Add sponge padding for comfort and to maintain the shape.

2. Arms and Legs:
   1. Create cylindrical shapes for the arms and legs using EVA foam. Ensure the wrist and ankle areas are slightly smaller for a tapered look.
   2. Add details like elbow and knee pads by cutting smaller foam pieces and attaching them.

3. Constructing the Helmet

1. Basic Shape:
   1. Start with a strip of EVA foam that goes from the front to the back of the head. Add two side strips and then four horizontal strips around the jawline and back of the head.
   2. Fill in the gaps with more foam pieces to cover the entire head.

2. Visor and Ears:
   1. Create a visor template from paper, transfer it to the foam, and cut it out. Ensure the visor is larger than the wearer’s head for comfort.
   2. For the ears, cut out circular shapes from EVA foam, dremel the edges, and attach them to the sides of the helmet. Use a heat gun to expand the cuts for a more detailed look.

4. Painting and Detailing

1. Sealing the Foam:
   1. Seal all foam pieces with Mod Podge or Plasti Dip to ensure the paint adheres well and to give the foam a smooth finish.

2. Painting:
   1. Apply a base coat of white or red acrylic paint, depending on the version of Baymax you are creating.
   2. Add details such as the black eyes, access port, and any other markings using a fine brush.

3. Finishing Touches:
   1. Once the paint is dry, apply a clear coat to protect the paint job and give it a glossy finish.

5. Assembly and Wearing

1. Assembling the Costume:
   1. Use elastic bands or Velcro strips to attach the different parts of the costume securely. Ensure that the costume is comfortable and allows for movement.
   2. Add sponge or foam padding inside the costume for additional comfort and to maintain the shape.

2. Undergarments:
   1. Wear black clothing underneath the costume to ensure any gaps between the foam pieces are not noticeable.

6. Optional Enhancements

1. Articulated Fingers:
   1. For a more advanced build, create articulated fingers using strings and dowels. This will allow the fingers to move realistically.

2. Internal Fan:
   1. If you plan on wearing the costume for extended periods, consider installing a small fan inside the chest area to keep cool.

Resources and References

• Crazecosplay.com and Rank No.1: These websites offer ready-made Baymax costumes and accessories that can serve as a base or inspiration for your build.
• Instructables and YouTube Tutorials: There are numerous tutorials available online that provide step-by-step instructions and visual aids for constructing Baymax costumes.

Conclusion